Shop Manual Komatsu WA200-6

SEN03081-02
WHEEL LOADER
WA200 -6
SERIAL NUMBERS 70001 and up
SEN03090-02
WHEEL LOADER 1SHOP MANUAL
WA200-6
Machine model Serial number
WA200-6 70001 and up
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
WA200-6 1
SEN03090-02 00 Index and foreword
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN03081-02
00 Index and foreword SEN03082-02

Index SEN03090-02 q
Foreword and general information SEN03091-00
01 Specification SEN03083-00
Specification and technical data SEN03092-00
10 Structure, function and maintenance standard SEN03084-00

Engine and cooling system SEN03250-00
Power train SEN03251-00
Steering system SEN03252-00
Brake system SEN03253-00
Undercarriage and frame SEN03254-00
Hydraulic system SEN03255-00
Work equipment SEN03256-00
Cab and its attachments SEN03257-00
Electrical system, Part 1 SEN03258-00
20 Standard value table SEN03085-00

Standard service value table SEN03731-00
30 Testing and adjusting SEN03086-00

Testing and adjusting, Part 1 SEN03732-00
40 Troubleshooting SEN03087-00
Failure code table and fuse locations SEN03735-00
General information on troubleshooting SEN03736-00
Troubleshooting by failure code (Display of code), Part 1 SEN03737-00
2 WA200-6

Troubleshooting of electrical system (E-mode) SEN03744-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03745-00
Troubleshooting of engine (S-mode) SEN03746-00
50 Disassembly and assembly SEN03088-00

General information on disassembly and assembly SEN03786-00 Q
Engine and cooling system SEN03787-00 Q
Power train, Part 1 SEN03788-00 Q
Power train, Part 2 SEN03789-00 Q
Undercarriage and frame SEN03790-00 Q
Hydraulic system SEN03791-00 Q
Work equipment SEN03792-00 Q
Cab and its attachments SEN03793-00 Q
Electrical system SEN03794-00 Q
90 Diagrams and drawings SEN03089-01

Hydraulic diagrams and drawings SEN03093-00
Electrical diagrams and drawings SEN03094-01
WA200-6 3
Table of contents 1
00 Index and foreword

Index SEN03090-02
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN03091-00
Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN03092-00
Specification dimension drawing ................................................................................................. 3
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 8
Table of fuel, coolant and lubricants ............................................................................................ 10
10 Structure, function and maintenance standard

Engine mount and transfer mount ............................................................................................... 2
Damper........................................................................................................................................ 3
Cooling system............................................................................................................................ 4
Cooling system hydraulic piping diagram.................................................................................... 5
Cooling fan motor ........................................................................................................................ 7
Power train SEN03251-00
Power train .................................................................................................................................. 3
Power train system diagram........................................................................................................ 4
Drive shaft ................................................................................................................................... 6
HST hydraulic piping diagram ..................................................................................................... 7
HST pump ................................................................................................................................... 8
HST motor ................................................................................................................................... 16
Transfer ....................................................................................................................................... 22
Clutch solenoid valve .................................................................................................................. 33
Axle ............................................................................................................................................. 34
Differential ................................................................................................................................... 36
Torque proportioning differential.................................................................................................. 41
Limited slip differential................................................................................................................. 44
Final drive.................................................................................................................................... 48
Steering system SEN03252-00
Steering piping diagram............................................................................................................... 3
Steering column........................................................................................................................... 4
Priority valve................................................................................................................................ 5
Orbit-roll valve ............................................................................................................................. 8
2-way restrictor valve .................................................................................................................. 16
Cushion valve.............................................................................................................................. 17
Steering cylinder.......................................................................................................................... 18
Emergency steering piping diagram............................................................................................ 20
Emergency steering valve ........................................................................................................... 21
Steering relief valve ..................................................................................................................... 24
4 WA200-6
Brake system SEN03253-00

Brake piping diagram .................................................................................................................. 3
Charge valve ............................................................................................................................... 4
Brake valve ................................................................................................................................. 8
Inching valve ............................................................................................................................... 12
Accumulator (for brake)............................................................................................................... 13
Slack adjuster.............................................................................................................................. 14
Brake........................................................................................................................................... 16
Parking brake control .................................................................................................................. 21
Parking brake .............................................................................................................................. 22
Axle mount and center hinge pin................................................................................................. 2
Work equipment hydraulic piping diagram .................................................................................. 2
Work equipment control lever linkage ......................................................................................... 4
Hydraulic tank ............................................................................................................................. 6
4-gear pump................................................................................................................................ 8
Work equipment control valve ..................................................................................................... 11
PPC valve ................................................................................................................................... 27
Lock valve ................................................................................................................................... 36
Accumulator (for PPC circuit)...................................................................................................... 37
ECSS valve ................................................................................................................................. 38
Accumulator (for ECSS).............................................................................................................. 40
Work equipment linkage.............................................................................................................. 2
Bucket ......................................................................................................................................... 4
Bucket positioner and boom kick-out .......................................................................................... 6
Work equipment cylinder............................................................................................................. 12
Cab.............................................................................................................................................. 3
Air conditioner ............................................................................................................................. 4
Machine monitor system ............................................................................................................. 2
Machine monitor.......................................................................................................................... 6
Electrical system (HST controller system) .................................................................................. 2
HST controller ............................................................................................................................. 18
ECSS system .............................................................................................................................. 19
KOMTRAX system ...................................................................................................................... 20
Engine starting circuit .................................................................................................................. 22
Engine stopping circuit ................................................................................................................ 24
Preheating circuit ........................................................................................................................ 25
Engine output derating function .................................................................................................. 26
Automatic warm-up function........................................................................................................ 26
Parking brake circuit.................................................................................................................... 28
Max. traction switch..................................................................................................................... 30
Sensor......................................................................................................................................... 31
20 Standard value table

Standard service value table SEN03731-00
Standard service value table for engine ...................................................................................... 2
Standard service value table for chassis ..................................................................................... 3
WA200-6 5
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed ............................................................................................................. 8
Measuring exhaust gas color ...................................................................................................... 10
Adjusting valve clearance............................................................................................................ 12
Measuring compression pressure ............................................................................................... 14
Measuring blow-by pressure ....................................................................................................... 17
Testing engine oil pressure.......................................................................................................... 18
Measuring intake air (boost) pressure......................................................................................... 19
Handling fuel system equipment ................................................................................................. 21
Releasing residual pressure in fuel system................................................................................. 21
Measuring fuel pressure.............................................................................................................. 22
Measuring fuel return rate and leakage....................................................................................... 24
Bleeding air from fuel circuit ........................................................................................................ 28
Testing leakage in fuel system .................................................................................................... 29
Handling reduced cylinder mode operation................................................................................. 30
Handling no-injection cranking operation .................................................................................... 30
Handling controller voltage circuit ............................................................................................... 31
Check of muffler and muffler stack for looseness and damage................................................... 31
Check of muffler function............................................................................................................. 32
Check of installed condition of cylinder head and manifolds....................................................... 32
Check of engine piping for damage and looseness .................................................................... 33
Testing and adjusting air conditioner compressor belt tension.................................................... 33
Replacing alternator belt ............................................................................................................. 34
Checking operating force of accelerator pedal............................................................................ 3
Checking directional lever ........................................................................................................... 4
Testing and adjusting HST oil pressure....................................................................................... 5
Testing clutch control pressure.................................................................................................... 9
Testing and adjusting steering wheel .......................................................................................... 10
Testing and adjusting steering oil pressure ................................................................................. 12
Bleeding air from steering circuit ................................................................................................. 14
Testing hydraulic fan.................................................................................................................... 15
Measuring brake pedal................................................................................................................ 17
Testing and adjusting brake pedal linkage .................................................................................. 18
Measuring brake performance .................................................................................................... 19
Testing and adjusting accumulator charge pressure ................................................................... 20
Testing wheel brake oil pressure ................................................................................................. 22
Testing wear of brake disc........................................................................................................... 25
Bleeding air from wheel brake circuit .......................................................................................... 26
Releasing residual pressure in brake accumulator circuit ........................................................... 27
Testing parking brake performance ............................................................................................. 28
Testing and adjusting parking brake control cable ...................................................................... 29
Measuring and adjusting work equipment control lever .............................................................. 30
Testing and adjusting work equipment hydraulic pressure.......................................................... 31
Testing work equipment PPC oil pressure................................................................................... 32
Bleeding air from hydraulic circuit ............................................................................................... 34
Releasing remaining pressure in hydraulic circuit ....................................................................... 35
Testing and adjusting bucket positioner ...................................................................................... 36
Testing and adjusting of boom kick-out switch ............................................................................ 38
Checking proximity switch operation pilot lamp........................................................................... 39
Procedure for testing diodes ....................................................................................................... 40
Preparation work for troubleshooting for electric system ............................................................ 42
Starting KOMTRAX terminal operations...................................................................................... 46
Indicator lamps of KOMTRAX terminal ....................................................................................... 50
6 WA200-6

Adjusting machine monitor.......................................................................................................... 2
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor .......... 3
Special functions of machine monitor (EMMS) ........................................................................... 5
Pm clinic inspection chart............................................................................................................ 59
40 Troubleshooting
Failure code table and fuse locations SEN03735-00
Failure codes table...................................................................................................................... 2
Fuse locations ............................................................................................................................. 8
General information on troubleshooting SEN03736-00
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Testing before troubleshooting .................................................................................................... 4
Classification and procedures of troubleshooting ....................................................................... 5
Information contained in troubleshooting table............................................................................ 8
Connection table for connector pin numbers .............................................................................. 10
T- branch box and T- branch adapter table ................................................................................. 46
Failure code [2G40GZ] Brake: Oil pressure reduction.................................................................. 2
Failure code [6091NX] HST filter: Clogging .................................................................................. 4
Failure code [989FN1] Travel speed: Overrun alarm.................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short ................................................................. 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage . 8
Failure code [B@BAZG] Engine: Oil pressure reduction.............................................................. 10
Failure code [B@BCNS] Engine: Overheat .................................................................................. 11
Failure code [B@BCZK] Engine: Low coolant level...................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature.......................................................... 14
Failure code [B@CRNS] HST: High oil temperature..................................................................... 15
Failure code [CA111] Abnormality in engine controller................................................................ 3
Failure code [CA115] Engine Ne or Bkup speed sensor error .................................................... 4
Failure code [CA122] Charge pressure sensor high error .......................................................... 6
Failure code [CA123] Charge pressure sensor low error............................................................ 8
Failure code [CA131] Throttle sensor high error ......................................................................... 10
Failure code [CA132] Throttle sensor low error .......................................................................... 12
Failure code [CA144] Coolant sensor high error......................................................................... 14
Failure code [CA145] Coolant sensor low error .......................................................................... 16
Failure code [CA153] Charge temperature sensor high error ..................................................... 18
Failure code [CA154] Charge temperature sensor low error ...................................................... 20
Failure code [CA155] Derating of speed by abnormally high charge temperature ..................... 22
Failure code [CA187] Sensor power supply 2 low error .............................................................. 24
Failure code [CA221] Atmospheric pressure sensor high error .................................................. 26
Failure code [CA222] Atmospheric sensor low error................................................................... 28
Failure code [CA227] Sensor power supply 2 high error ............................................................ 30
Failure code [CA234] Engine overspeed .................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error ....................................................... 32
Failure code [CA271] IMV (IMA) Short circuit ............................................................................. 33
Failure code [CA272] IMV (IMA) Disconnection.......................................................................... 34
Failure code [CA322] Injector #1 open/short error ...................................................................... 36
Failure code [CA342] Calibration code inconsistency................................................................. 44
Failure code [CA351] Injectors drive circuit error ........................................................................ 46
Failure code [CA352] Sensor power supply 1 low error .............................................................. 48
Failure code [CA386] Sensor power supply 1 high error ............................................................ 50
WA200-6 7

Failure code [CA428] Abnormally high level in water sensor ...................................................... 4
Failure code [CA429] Abnormally low level in water sensor ....................................................... 6
Failure code [CA431] Idle validation switch error ........................................................................ 8
Failure code [CA432] Idle validation action error ........................................................................ 12
Failure code [CA435] Engine oil pressure switch error ............................................................... 16
Failure code [CA441] Battery voltage low error........................................................................... 17
Failure code [CA442] Battery voltage high error ......................................................................... 20
Failure code [CA449] Common rail pressure high error 2........................................................... 22
Failure code [CA451] Common rail pressure sensor high error .................................................. 24
Failure code [CA452] Common rail pressure sensor low error ................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature ..................... 28
Failure code [CA553] Common rail pressure high error 1........................................................... 29
Failure code [CA559] Supply pump pressure very low error....................................................... 30
Failure code [CA689] Engine Ne speed sensor error.................................................................. 32
Failure code [CA731] Engine Bkup speed sensor phase error ................................................... 34
Failure code [CA757] All continuous data lost error .................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error .............................................................. 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................. 40
Failure code [CA2185] Throttle sensor supply voltage high error ............................................... 44
Failure code [CA2186] Throttle sensor power supply low error .................................................. 46
Failure code [CA2249] Supply pump pressure very low error 2.................................................. 48
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ......................................................... 50
Failure code [CA2555] Intake heater relay disconnection error .................................................. 52
Failure code [CA2556] Intake heater relay short circuit error ...................................................... 54
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short.......................................... 4
Failure code [D192KY] ECSS solenoid relay: Hot short.............................................................. 6
Failure code [D1B0KA] HST safety relay: Disconnection............................................................ 8
Failure code [D1B0KB] HST safety relay: Ground fault .............................................................. 10
Failure code [D1B0KY] HST safety relay: Hot short.................................................................... 12
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ........................................... 14
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection ................................ 16
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection............................... 18
Failure code [DAJ0KK] HST controller power supply: Low voltage............................................. 22
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................. 24
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................. 26
Failure code [DAJ1L6] HST controller main power line: Hot short .............................................. 28
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage...................................... 30
Failure code [DAJ2L3] HST controller load power supply holding line:
Hot short in wiring harness................................................................................................... 32
Disconnection/Ground fault.................................................................................................. 34
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range ....................................... 36
Failure code [DAJ9KQ] HST controller model selection:
Disagreement of model selection signals............................................................................. 38
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ................................... 39
Failure code [DAJRMA] HST controller: Disagreement in option selection................................. 45
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line ..................... 3
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality................................. 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality................................................. 10
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short ................................. 12
Failure code [DDB6KB] Parking brake switch B: Ground fault.................................................... 14
Failure code [DDB6KZ] Parking brake switch (bottom switch) or
parking brake reminder switch (intermediate switch): Trouble ............................................. 16
Failure code [DDB6L0] Parking brake switch A: Ground fault..................................................... 18
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short .................................. 20
8 WA200-6
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ............... 22
Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................ 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection.......................... 26
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault ................................................ 28
Failure code [DDK6KY] FNR lever: Hot short ............................................................................. 32
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering).............. 34
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault .......... 3
Failure code [DF10KB] Travel speed range selector switch: Hot short....................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault............................................ 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.......................................... 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ....................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault.......................... 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short....................................................... 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................ 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short............................................ 18
Failure code [DLT3KX] Travel speed sensor B: Abnormality ...................................................... 20
Failure code [DLT4KX] Travel speed sensor A: Abnormality ...................................................... 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality................................................ 26
Failure code [DV00KY] Alarm buzzer: Hot short......................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault...................................... 30
Failure code [DW26KY] Motor 2 solenoid: Hot short .................................................................. 32
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................. 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault .................... 36
Failure code [DX16KA] Fan EPC solenoid: Disconnection ......................................................... 3
Failure code [DX16KB] Fan EPC solenoid: Ground fault............................................................ 4
Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................. 5
Failure code [DX19KA] Motor 1 solenoid: Disconnection ........................................................... 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault .............................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short ................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection ..................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault........................................................ 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................. 16
Failure code [DXH7KB] Reverse solenoid: Ground fault ............................................................ 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short .......................................... 20
Failure code [DXH8KB] Forward solenoid: Ground fault............................................................. 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short .......................................... 24
Failure code [J141N1] Steering pump: Overrun alarm................................................................ 26
Failure code [M100N1] HST pump: Overrun alarm..................................................................... 26
Failure code [M400N1] Motor 1: Overrun alarm.......................................................................... 27
Troubleshooting of electrical system (E-mode) SEN03744-00
E-1 Engine does not start............................................................................................................ 3
E-2 Preheater does not operate normally ................................................................................... 10
E-3 Defective boom kick-out function and cancellation............................................................... 14
E-4 Defective bucket positioner function and cancellation.......................................................... 18
E-5 Defective lift arm FLOATING holding function and cancellation ........................................... 22
E-6 Travel direction selection system does not function ............................................................. 26
E-7 Wiper does not operate ........................................................................................................ 30
E-8 Windshield washer does not operate ................................................................................... 34
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off........................................ 38
E-10 Working lamp does not light up or go off ............................................................................ 46
E-11 Turn signal lamp and hazard lamp do not light up or go off ................................................ 51
E-12 Brake lamp does not light or it keeps lighting up ................................................................ 58
E-13 Backup lamp does not light or it keeps lighting up ............................................................. 60
E-14 Backup alarm does not sound or it keeps sounding ........................................................... 63
E-15 Horn does not sound or it keeps sounding ......................................................................... 66
E-16 Alarm buzzer does not sound or it keeps sounding............................................................ 68
WA200-6 9
E-17 Air conditioner does not operate or stop............................................................................. 70

E-18 The KOMTRAX system does not work properly ................................................................. 73
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03745-00
Method of using troubleshooting chart .......................................................................................... 3
Failure code and cause table ........................................................................................................ 6
H-1 The machine does not start .................................................................................................... 8
H-2 The travel speed is slow ......................................................................................................... 9
H-3 The traction force is weak....................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively........................................... 11
H-5 Speed range is not shifted ...................................................................................................... 12
H-6 The steering wheel does not turn ........................................................................................... 13
H-7 The steering wheel is heavy ................................................................................................... 14
H-8 Steering wheel shakes or jerks............................................................................................... 15
H-9 Machine deviates naturally to one side when traveling .......................................................... 15
H-10 The brake does not work or does not work well ................................................................... 16
H-11 The brake is not released or is dragged ............................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height........................................ 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) .................. 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................. 20
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily.. 21
H-19 The bucket does not tilt back ................................................................................................ 22
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................... 24
H-23 Hydraulic drifts of the bucket occur often.............................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”). 24
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy .................. 25
H-27 The ECSS does not operate and machine pitches and bounces......................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 27
Troubleshooting of engine (S-mode) SEN03746-00
Method of using troubleshooting charts ...................................................................................... 2
S-1 Starting performance is poor................................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly ........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive ........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23
50 Disassembly and assembly

General information on disassembly and assembly SEN03786-00
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Special tool list............................................................................................................................. 7
10 WA200-6
Sketches of special tools............................................................................................................. 11

Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 5
Removal and installation of cylinder head assembly .................................................................. 12
Removal and installation of engine hood assembly .................................................................... 25
Removal and installation of radiator ............................................................................................ 29
Removal and installation of air aftercooler .................................................................................. 32
Removal and installation of hydraulic oil cooler assembly .......................................................... 34
Removal and installation of engine assembly ............................................................................. 36
Removal and installation of engine front oil seal assembly......................................................... 43
Removal and installation of engine rear oil seal assembly ......................................................... 46
Removal and installation of cooling fan and fan motor assembly ............................................... 49
Removal and installation of fuel tank assembly .......................................................................... 52
Power train, Part 1 SEN03788-00
Disassembly and assembly of transfer assembly ....................................................................... 2
Removal and installation of parking brake assembly .................................................................. 21
Disassembly and assembly of parking brake assembly.............................................................. 23
Power train, Part 2 SEN03789-00
Removal and installation of front axle assembly ......................................................................... 2
Removal and installation of rear axle assembly .......................................................................... 4
Disassembly and assembly of axle housing assembly ............................................................... 7
Disassembly and assembly of differential assembly ................................................................... 15
Removal and installation of center hinge pin .............................................................................. 2
Removal and installation of counterweight assembly ................................................................. 11
Removal and installation of HST pump and 4-gear pump assembly .......................................... 2
Disassembly and assembly of HST pump assembly .................................................................. 6
Removal and installation of HST motor 1 assembly ................................................................... 33
Removal and installation of HST motor 2 assembly ................................................................... 35
Disassembly and assembly of HST motor assembly .................................................................. 37
Removal and installation of work equipment control valve assembly ......................................... 53
Removal and installation of hydraulic tank .................................................................................. 55
Disassembly and assembly of hydraulic cylinder assembly........................................................ 57
Removal and installation of work equipment assembly .............................................................. 2
Removal and installation of operator's cab and floor frame assembly ........................................ 2
Removal and installation of operator's cab glass (Stuck glass) .................................................. 7
Removal and installation of air conditioner unit........................................................................... 15
Electrical system SEN03794-00
Removal and installation of monitor panel .................................................................................. 2
Removal and installation of engine controller assembly ............................................................. 4
Removal and installation of HST controller assembly ................................................................. 6
Removal and installation of KOMTRAX terminal assembly ........................................................ 7
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN03093-00
Hydraulic circuit diagram............................................................................................................. 3
Electrical diagrams and drawings SEN03094-01
Electrical circuit diagram ............................................................................................................. 3
Connector arrangement diagram ................................................................................................ 23
WA200-6 11
SEN03090-02
WA200-6 Wheel loader

Form No. SEN03090-02
©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)
12
SEN03091-00
WA200-6
WA200-6 70001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
WA200-6 1
Safety notice 1 (Rev. 2007/03)

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 WA200-6
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
WA200-6 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 WA200-6
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
WA200-6 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 WA200-6
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
WA200-6 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 WA200-6
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WA200-6 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 WA200-6
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
WA200-6 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 WA200-6
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
WA200-6 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 WA200-6
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WA200-6 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 WA200-6
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WA200-6 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 WA200-6
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA200-6 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 107 – 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 – 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 WA200-6
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WA200-6 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 WA200-6
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WA200-6 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 WA200-6
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
WA200-6 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 WA200-6
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
WA200-6 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 WA200-6
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA200-6 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 WA200-6
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
WA200-6 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 WA200-6
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WA200-6 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 WA200-6
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
WA200-6 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 WA200-6
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA200-6 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 WA200-6
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA200-6 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 WA200-6
WA200-6 41
SEN03091-00

©2007 KOMATSU
All Rights Reserved
42
SEN03092-00
WA200-6
WA200-6 70001 and up
01 Specification 1
Specification and technical data

Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
WA200-6 1
SEN03092-00 01 Specification
2 WA200-6
Specification dimension drawing 1
Item Unit WA200-6

Machine weight (with BOC) kg 9,555
Normal load kN {kg} 31.4 {3,200}
Bucket capacity (heaped, with BOC) m3 2.0
Engine model — Komatsu SAA4D107E-1 Diesel engine
Engine rated output
•Net [ISO 9249/SAE J1349] (*1) kW{HP}/rpm 94 {126}/2,000
•Gross [SAE J1955] (*2) 95.2 {128}/2,000
A Overall length (with BOC) mm 6,985
B Overall height mm 3,110
C Overall height with bucket lifted up mm 4,885
D Overall width mm 2,375
E Minimum ground clearance mm 425
F Bucket width mm 2,550
G Dumping clearance Bucket tip/BOC tip mm 2,820/2,760
H Dumping reach Bucket tip/BOC tip mm 975/1,000
I Dumping angle degree 45
Min. turning radius Bucket tip/BOC tip mm 5,830/5,850
Center of outside tire mm 5,100
Permissible towing load kN {kg} 71.0 {7,250}
1st (forward/reverse) 4.0 – 13.0/4.0 – 13.0
2nd (forward/reverse) 13.0/13.0
Travel speed km/h
3rd (forward/reverse) 20.0/20.0
4th (forward/reverse) 34.5/34.5
*1: Indicates the value at the lowest cooling fan speed.
*2: Indicates the value of the engine alone (without cooling fan).
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
91 kW {122 HP}/2,000 rpm
a BOC: Abbreviation for Bolt-On Cutting edge
WA200-6 3
Specifications 1
Machine model name WA200-6

Serial No. 70001 and up
Machine weight kg 9,555
Machine weight (front wheel) in
Weight
kg 3,785
SAE travel posture
Machine weight (rear wheel) in
kg 5,770
SAE posture
Bucket capacity (heaped) m3 2.0
Normal load kN {kg} 31.4 {3,200}
Travel speed
• Forward 1st 4.0 – 13.0
• Forward 2nd 13.0
km/h
• Forward 3rd 20.0
• Forward 4th 34.5
• Reverse 1st 4.0 – 13.0
Performance
• Reverse 2nd 13.0

km/h
• Reverse 3rd 20.0
• Reverse 4th 34.5
Max. traction force
• Forward 86 {8,800}
kN{kg}
• Reverse 86 {8,800}
Gradeability deg. 25
Min. turning radius
mm 5,100
(center of outside tire)
Turning radius (cutting edge/BOC tip),
mm 5,830/5,850
SAE travel posture
Overall length (with BOC) mm 6,895
Overall width (chassis) mm 2,375
Bucket width (with BOC) mm 2,550
Overall height (cab top) mm 3,110
Overall height with bucket lifted up mm 4,885
Wheelbase mm 2,840
Tread mm 1,930
Minimum ground clearance mm 425
Dimension
Max. hinge pin height mm 3,685

Dumping clearance
mm 2,820/2,760
(cutting edge/BOC tip)
Dumping reach
mm 975/1,000
Steering angle deg. 38 (frame stopper 40)
Bucket tilt-back angle
deg. 48/67
(operating posture/Max. height)
Bucket tilt-forward angle
deg. 45
(max. height)
Digging depth, 10°
mm 285/320
4 WA200-6

Model SAA4D107E-1
4-cycle, water-cooled, in-line 4-cylinder, direct injection type
Type
with turbocharger and air-cooled aftercooler
Cylinder bore x Cylinder stroke mm 107 x 124
Total piston displacement l {cc} 4.46 {4,460}
Rated output
• Net [ISO 9249/SAE J1349] (*1) 94 {126}/2,000
kW{HP}/rpm
• Gross [SAE J1995] (*2) 95.2 {128}/2,000
Engine
Performance
Max. torque (*1) Nm{kgm}/rpm 584 {59.6}/1,400

g/kWh
Min. fuel consumption 219 {161}
{g/HPh}
Max. speed at no load rpm 2,250
Min. speed at no load rpm 825
Starting motor 24 V, 4.5 kW
Alternator 24 V, 60 A
Battery (*3) 12 V, 88 Ah, 2 pieces
HST pump
• Type Variable displacement swash plate type piston pump
• Pump capacity cc/rev 0 – 90
HST motor 1
• Type Variable displacement bent axis type piston motor
• Pump capacity cc/rev 0 – 80
Power train
HST motor 2
• Type Variable displacement bent axis type piston motor
• Pump capacity cc/rev 46.5 – 80
Counter-shaft double acting planetary type, spur gear
Transfer
constant-mesh type, switching between 2 power trains
Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type, torque proportioning
Final drive Planetary gear single reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle
Front axle Fixed frame, semi-float type

Rear axle Center pin support type, semi-float type
Size 17.5–25–12PR
Rim size 25 x 13.00
Tire
Inflation pressure
• Front wheel kPa 294 {3.0}
• Rear wheel {kg/cm2} 294 {3.0}
*1:
Indicates the value at the lowest cooling fan speed.
*2:
Indicates the value of the engine alone (without cooling fan).
*3:
The battery capacity (Ah) is indicated in the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
91 kW {122 HP}/2,000 rpm
WA200-6 5

Braking method 4-wheel brake, independent front and rear wheel brakes
Type of brake Enclosed wet multiple disc type
Main
Drive method Hydraulic drive

Operating method Foot-operated (with hydraulic booster)
Brake
Braking method Transmission output shaft brake

Parking
Type of brake Wet multiple disc type

Drive method Mechanical type
Operating method Manual lever type
Steering
Steering method Articulated chassis type
Drive method Hydraulic drive

Steering pump
• Type Gear type
• Delivery cm3/rev 50.1
Work equipment pump
Hydraulic pump
• Type Gear type

• Delivery cm /rev
3
32.0
Brake and cooling fan pump
• Type Gear type
• Delivery cm3/rev 12.4
Transfer lubrication pump
• Type Gear type
• Delivery cm /rev
3
12.4
Type Double-acting piston type
Cylinder bore mm 70
Steering cylinder
Hydraulic equipment
Piston rod outside diameter mm 40

Stroke mm 453
Max. distance between centers
mm 1,271
of pins
Min. distance between centers
mm 818
of pins
Cylinder bore mm 120
Lift cylinder

Cylinder
Stroke mm 673.5
mm 1,817.5
of pins
mm 1,144
of pins
Cylinder bore mm 130
Bucket cylinder

Stroke mm 493
mm 1,447
of pins
mm 954
of pins
6 WA200-6

Work equipment control valve
Control valve
• Type 2-spool type

• Set pressure MPa{kg/cm } 2
20.6 {210}
Steering valve
equipment
Hydraulic
• Type Orbit-roll type

• Set pressure MPa{kg/cm2} 20.6 {210}
Cooling fan motor
Motor
Fixed displacement, swash plate, piston type

• Type
<with reversible valve and flow control valve>
• Motor capacity cm3/rev 11.5
equipment
Type of link Single link

Work
Shape of bucket cutting edge Straight cutting edge with BOC
WA200-6 7
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine (excluding coolant and oil) 470
Damper 3
Cooling assembly (excluding coolant and oil) 69
• Radiator 10
• Oil cooler 9
• Aftercooler 10
Transfer oil cooler 3
Cooling fan motor 13
HST pump 67
HST motor 1 34
HST motor 2 34
Transfer 214
Front drive shaft 15
Rear drive shaft 4
Front axle
• With torque proportioning differential 522
• With limited slip differential 526
Rear axle
• With torque proportioning differential 492
• With limited slip differential 496
Axle pivot (Rear axle) 79
Wheel [25 x 13.00 ] (1 piece) 77
Tire [17.5–25–12 PR] (1 piece) 132
Hydraulic tank (excluding hydraulic oil) 77
4-gear pump 21
Work equipment control valve 19
Work equipment PPC valve 3
Priority valve 6
Orbit-roll valve 7
Cushion valve 4
Charge valve 6
Brake valve 10
Steering cylinder assembly (1 piece) 20
Lift cylinder assembly (1 piece) 77
Bucket cylinder assembly 76
Front frame 750
Rear frame 670
Counterweight 1,175
Additional counterweight (1 piece) 151
Engine hood (including side panel) 177
Fuel tank (excluding fuel) 97
8 WA200-6
Unit: kg
Lift arm (including bushing) 540
Bucket link 23
Bell crank 140
Bucket (2.0 m3, including BOC) 785
Operator's cab
800
(including air conditioner and interior parts)
Operator seat 41
Air conditioner unit 5
Battery (1 piece) 33
WA200-6 9
Table of fuel, coolant and lubricants 1
a For details of notes (Notes 1 and 2…) in the table, see "Operation and Maintenance Manual".
10 WA200-6
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 17 15.5
Transfer case 6.5 5.0
Hydraulic system 120 58
Axle (front/rear) 18 18
Cooling system 17 —
Fuel tank 177 —
WA200-6 11
SEN03092-00

©2007 KOMATSU
All Rights Reserved
12
SEN03250-00
WA200-6
WA200-6 70001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system

Engine mount and transfer mount................................................................................................................... 2
Damper ........................................................................................................................................................... 3
Cooling system ............................................................................................................................................... 4
Cooling system hydraulic piping diagram ....................................................................................................... 5
Cooling fan motor............................................................................................................................................ 7
WA200-6 1
SEN03250-00 10 Structure, function and maintenance standard
Engine mount and transfer mount 1
2 WA200-6
Damper 1
Unit: mm
No. Check item Criteria Remedy
Distance between HST pump Standard size Repair limit

1 installation surface and boss tip
Adjust
75.1 ±0.8
Wear on internal teeth of coupling
2 (resin)
Repair limit: 1.0 Replace
3. Coupling Outline
4. Boss q The damper protects the drive systems on and
5. HST pump input shaft after the engine from torsional vibrations by
6. Cover reducing the torsional vibrations of the engine
7. Flywheel due to the fluctuations in torque.
q The power from the engine is transmitted to
coupling (3) through flywheel (7), absorbing
torsional vibrations on coupling (3). Then it is
transmitted to HST pump through boss (4).
WA200-6 3
Cooling system 1
1. Reservoir tank 5. Aftercooler

2. Oil cooler 6. Transfer oil cooler
3. Radiator cap 7. Cooling fan
4. Radiator 8. Cooling fan motor
Specifications
Radiator Oil cooler Aftercooler
Core type AL WAVE-4 CF40-1 AL WAVE
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
Total heat dissipation area
29.86 4.15 x 2 10.87
(m2)
Pressure valve cracking pressure 68.6
— —
(kPa {kg/cm2}) {0.7}
Vacuum valve cracking pressure 0 – 4.9
— —
(kPa {kg/cm2}) {0 – 0.05}
4 WA200-6
Cooling system hydraulic piping diagram 1
1. Cooling fan motor Outline

2. Strainer q Cooling fan motor (1) installed in the machine
3. Hydraulic tank rear side is driven by oil pressure from brake
4. Brake and cooling fan pump and cooling fan pump (4).
5. Charge valve
WA200-6 5
6 WA200-6
Cooling fan motor 1
Type: LMF16
P: From pump through charge valve Specifications

T: To hydraulic tank through return filter Type: LMF16
TC: To hydraulic tank Capacity: 11.5 cm3/rev
Rated speed: 1,700 rpm
1. ER terminal Rated flow rate: 19.6 l/min
2. EF terminal Check valve cracking pressure:
3. Solenoid proportional pilot valve 0.013 MPa {0.13 kg/cm2}
4. ON/OFF pilot valve
WA200-6 7
8 WA200-6
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool
Unit: mm
No. Item Criteria Remedy

Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
18 Spool return spring diameter
length If damaged or
deformed, replace
58.8 N 47.1 N spring
44.84 x 12 33 —
{6 kg} {4.8 kg}
44.1 N 35.3 N
19 Spool return spring 35 x 8.5 34
{4.5 kg}
—
{3.6 kg}
WA200-6 9
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The pressurized oil from the hydraulic pump
flows through valve plate (7) into cylinder block
(5).
q This pressurized oil can flow on only to one
side of the (Y - Y) line connecting the top dead
center and bottom dead center of the stroke of
piston (4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (2 or 3 pistons).
q A single piston generates the force F1 [F1 (kg)
= P (kg/cm2) x xD2/4 (cm2)].
q This force works on thrust plate (2).
q Since thrust plate (2) is fixed to the specific
angle (a) to output shaft (1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y - Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.
10 WA200-6

1) Suction function (2) When the pump is stopped
q When the engine stops, the input revolution of
Function the pump becomes 0 rpm.
q If the fan pump stops, the pressurized oil does q The pressurized oil from the pump is not sup-
not flow into the motor. plied to port (P).
q Since the motor continues revolution because q As the pressurized oil is not supplied to (MA)
of the force of inertia, however, the pressure on side of the motor, the motor speed lowers
the outlet side of the motor rises. gradually to stop.
q When the pressurized oil stops flowing in from q If the motor shaft is revolved by the force of
inlet port (P), suction safety valve (1) sucks in inertia while the oil flow in port (P) is reducing,
the pressurized oil on the outlet side and sup- the oil in port (T) on the outlet side is sent by
plies it to port (MA) where there is not sufficient suction safety valve (1) to (MA) side to prevent
oil to prevent cavitation. cavitation.
Operation
(1) When pump is started
q The pressurized oil from the pump is supplied
to port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor,
the motor starts revolution.
q The pressurized oil on motor outlet (MB) side
of the motor returns through port (T) to the
tank.
WA200-6 11
2) Safety function
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Suction safety valve (1) is installed to protect
the fan system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of suction safety valve (1),
valve (2) of suction safety valve (1) opens to
release the pressurized oil into port (T).
q By this operation, generation of abnormally
high pressure in port (P) is prevented.
12 WA200-6
3. Operation of reversible valve

1) When the ON/OFF solenoid is 2) When the ON/OFF solenoid is energized
de-energized q When ON/OFF solenoid (1) is "energized",
q When ON/OFF solenoid (1) is "de-energized", valve (2) is switched.
the pressurized oil from the pump is shut off by q The pressurized oil from the pump flows to
valve (2). spool chamber (D) through port (C).
q Port (C) opens for the hydraulic tank circuit. q The pressurized oil in chamber (D) com-
q Spool (3) is pushed to the right by spring (4). presses spring (4).
q Port (MA) opens and pressurized oil flows in to q Spool (3) moves to the left.
revolve the motor in forward (clockwise). q Port (MB) opens and pressurized oil flows in to
rotate the motor in reverse (counterclockwise).
WA200-6 13
4. Flow control valve

(continuously-variable type)
Function
This valve supplies the necessary pump delivery to
the motor, and returns the excessive oil to the
hydraulic tank.
q The motor speed increases in proportion to the

increase of the incoming oil (Q) as shown in
Fig 1.
q When the incoming flow rate is (Q1), motor
speed becomes (B) rpm.
q In order to reduce noise and loss of the motor,
this valve keeps the fan speed constant inde-
pendent of the flow rate to the motor.
q Even if the flow rate is increased from (Q0) to
(Q1), the valve maintains the motor speed con-
stant between points (A) and (C).
Operation
q For the flow control valve, the upstream pres-
sure of the orifice is conducted to the right side
of spool (1) and the downstream pressure of
the orifice is led to its left side.
q The differential pressure before and after ori-
fice (E) by the incoming flow rate to the motor
works on spring (2).
q In Fig. 1, when the flow rate (Q0) is increased
beyond, the differential pressure before and
after spool (1) becomes larger than the
installed load of spring (2).
q Spool (1) moves to the left and port (P) is con-
nected to port (T).
q The excessive oil in (Z) portion of Fig 1 flows to
the hydraulic tank through the flow control
valve, and the motor speed is kept constant
from (A) to (C).
q This flow control valve is a continuously-vari-
able type.
q As shown in Fig 2, it is possible to change the
flow control valve continuously while maintain-
ing the motor speed constant between (A') to
( C ') by c ha n g i n g t h e c o m m an d c u r r e n t
between the motor speed (A) and (C).
14 WA200-6
WA200-6 15
SEN03250-00

©2007 KOMATSU
All Rights Reserved
16
SEN03251-00
WA200-6
WA200-6 70001 and up

Power train
Power train...................................................................................................................................................... 3
Power train system diagram ........................................................................................................................... 4
Drive shaft....................................................................................................................................................... 6
HST hydraulic piping diagram......................................................................................................................... 7
HST pump....................................................................................................................................................... 8
HST motor..................................................................................................................................................... 16
Transfer......................................................................................................................................................... 22
Clutch solenoid valve .................................................................................................................................... 33
Axle ............................................................................................................................................................... 34
Differential ..................................................................................................................................................... 36
Torque proportioning differential ................................................................................................................... 41
Limited slip differential .................................................................................................................................. 44
Final drive ..................................................................................................................................................... 48
WA200-6 1
2 WA200-6
Power train 1
1. Engine
2. Damper
3. HST pump
4. 4-gear pump
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
WA200-6 3
Power train system diagram 1
4 WA200-6
1. Engine Outline
2. Damper q The power from engine (1) is transmitted to
3. HST pump HST pump (3) after its torsional vibrations have
4. Steering pump been reduced with damper (2) installed on the
5. Work equipment pump flywheel.
6. Brake and cooling fan pump q The power from engine (1) is also transmitted
7. Transfer lubrication pump to HST pump (3) and the HST charge pump
8. High-pressure hose being built in HST pump (3) as well as steering
9. HST motor 1 pump (4), work equipment pump (5), brake
10. HST motor 2 and cooling fan pump (6) and transfer lubrica-
11. Emergency steering valve (if equipped) tion pump (7) being connected to HST pump
12. Transfer (3).
13. Transfer clutch q The directional selector valve and servo piston
14. Parking brake installed on HST pump (3) continuously modify
15. Front drive shaft the oil discharge direction and discharged
16. Front axle amount responding to inclination of the swash
17. Differential plate.
18. Wet multiple disc type brake q HST motors (9) and (10) are installed on trans-
19. Final drive fer (12) and connected to HST pump (3)
20. Front tire through high-pressure hose (8).
21. Rear drive shaft q The hydraulic power from HST pump (3)
22. Rear axle changes the rotating direction and speed of
23. Differential HST m oto rs (9) and (1 0) to cont ro l th e
24. Wet multiple disc type brake machine forward and reverse travel and travel
25. Final drive speed.
26. Rear tire q The power from HST motor 1 (9) is transmitted
to the output shaft through transfer clutch (13)
in transfer (12).
The power from HST motor 2 (10) is transmit-
ted to the output shaft through the gear in
transfer (12).
q As the parking brake lever is operated, parking
brake (14) being contained in the rear side of
transfer (12) activates the wet multiple disc
type brake to stop the machine.
q The power to the front side is transmitted to
front axle (16) through front drive shaft (15).
The power to the rear side is transmitted to
rear axle (22) through rear drive shaft (21).
q Speed of the power transmitted to axles (16)
and (22) is reduced on the pinion gear of differ-
entials (17) and (23), then transmitted to the
sun gear through the sun gear shaft.
q Speed of the power transmitted to the sun gear
is reduced on the planetary mechanism of final
drives (19) and (25), then transmitted to tires
(20) and (26) through the axle shaft and wheel.
WA200-6 5
Drive shaft 1
1. Front axle Outline

2. Front drive shaft q The power from the transfer output shaft is
3. Transfer transmitted to front axle (1) and rear axle (5)
4. Rear drive shaft through front drive shaft (2) and rear drive
5. Rear axle shaft (4).
q When the machine is articulated or when it
receives traveling impacts or working impacts,
the distances between the transfer and the
front and rear axles change. The drive shafts
absorb fluctuations in the angle and length with
the universal joints and slip joint so that the
power will be transmitted without damaging the
parts even when the machine is exposed to
above impacts or changes in the component
positions.
6 WA200-6
HST hydraulic piping diagram 1
1. Hydraulic tank
2. HST pump
3. HST drain oil filter
4. Clutch solenoid valve
5. HST oil filter
6. HST motor 1
7. HST motor 2
WA200-6 7
HST pump 1
a HST: Abbreviation for HydroStatic Transmission
1. Directional selector solenoid valve Specifications

2. High-pressure cutoff valve
Model name A4VG90DA
3. Speed-related valve (DA valve)
4. Charge pump Variable displacement
Type swash plate type piston
5. Low-pressure relief valve pump
6. Servo cylinder Theoretical delivery
7. High-pressure relief valve 0 – 90
(cc/rev)
8. Control plate High-pressure relief valve
9. Cylinder block set pressure 44.1 {450}
10. Piston (MPa {kg/cm2})
11. Swash plate High-pressure cutoff valve Effective differential
set pressure pressure
(MPa {kg/cm2}) 41.2 {420}
Low-pressure relief valve
set pressure 2.45 {25}
(MPa {kg/cm2})
8 WA200-6
Operation
Flow of power Flow of oil
q The HST pump is installed on the damper of q Inclination of swash plate (11) starts reciprocat-
the engine flywheel. ing movement of piston (10). The pumping
q The power from the engine is transmitted to action initiated by this reciprocating movement
the HST pump through the flywheel and suctions or discharges the oil in cylinder block
damper. (9) continuously.
q The HST pump is equipped with directional q The pumping action directs the oil flow in a cer-
selector solenoid valve (1) and servo cylinder tain definite direction so that it may flow to the
(6). HST motor.
q Driving the machine forward or reverse acti- q Reversing the inclination of swash plate (11)
vates directional selector solenoid valve (1), reverses the suction and discharge ports and,
tilting swash plate (11) and, as a result, caus- as a result, reversing the oil discharging direc-
ing the switch between the oil suction and dis- tion, too.
charge ports. q Piston (10) does not stroke when swash plate
q The HST pump is built-in cylinder block and 9 (11) is at neutral, thus the oil is not discharged.
pistons (10) rotate along with drive shaft (12). q Increasing or decreasing the inclination (angle)
q Tips of piston (10) slides on the swash plate of swash plate (11) changes the stroke of pis-
surface of swash plate (11) that does not ton (10), allowing to control the travel speed.
rotate. q If the amount of the oil in the low-pressure cir-
cuit (the oil to be returned from the motor to the
pump) becomes insufficient due to leakage of
oil in the HST pump, HST motor and control
valve, the charge pump supplies the oil
through speed-related valve (3) and the check
valve on high-pressure relief valve (7).
WA200-6 9
High-pressure relief valve 1
1. Nut Function
2. Locknut q This valve is installed on the HST pump. If the
3. Poppet spring oil pressure on the high pressure circuit side
4. Check spring across the HST pump and HST motor goes
5. Main piston beyond the set pressure, it drains the pressure
6. Valve seat to the low pressure circuit side.
7. Pilot poppet This valve sets the maximum pressure of the
8. Adjustment screw HST circuit in this manner to protect the circuit.
q If low level of the oil is detected in the circuit,
the valve conducts oil from the HST charge
pump in order to protect cavitation.
10 WA200-6
Operation
q Port (A) is connected to the high pressure cir- q As the oil pressure in chamber (B) goes lower,
cuit side of the HST pump, and ports (C) and the orifice of main piston (5) is activated and
(D) are connected to the low pressure circuit differential pressure is generated in port (A)
side of the pump. and chamber (B).
q Oil fills up chamber (B) after flowing through q The oil pressure in port (A) pushes main piston
the orifice of main piston (5). (5) in the left direction, relieving the abnormal
q Pilot poppet (7) is seated on valve seat (6). pressure generated in port (A) to port (C).
q If oil pressure in port (A) and chamber (B) goes q As the oil pressure in port (A) goes lower than
beyond the set pressure, pilot poppet (7) is that in port (C), check spring (4) pushes back
pushed in the left direction. As a result, the oil main piston (5) in the right direction.
pressure in chamber (B) is released to port (C) q The oil in port (C) is conducted to port (A)
through chamber (D) and the oil pressure in through chamber (D) so that the oil level in port
chamber (B) is decreased. (A) may not go low.
q Increasing or decreasing the repulsive force of
poppet spring (3) allows adjusting the set pres-
sure.
q When increasing the set pressure, remove the
nut to loosen the locknut and screw the adjust-
ment screw. When decreasing, loosen the
adjustment screw.
WA200-6 11
Low-pressure relief valve 1 q When increasing the set pressure, loosen lock-
nut (1) and screw adjustment screw (2). When
decreasing, loosen the adjustment screw.
1. Locknut
2. Adjustment screw
3. Piston
4. Spring
Function
q This valve is installed on the HST pump. If the
oil pressure on the low pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil to the
hydraulic tank.
This valve sets the oil pressure of the HST
pump charge circuit in this manner to protect
the circuit.
Operation
q Port (A) is connected to the HST pump charge

circuit and port (B) is connected to the drain
circuit.
q As long as port (A) is below the set pressure,
oil does not flow to port (B).
q If oil pressure in port (A) goes beyond the set
pressure, piston (3) is pushed in the right direc-
tion. As a result, the oil pressure in port (A) is
released to port (B) and the oil pressure in port
(A) is decreased.
q Increasing or decreasing the repulsive force of
spring (4) allows adjusting the set pressure.
12 WA200-6
HST charge pump 1
1. Cover bolt Specifications

2. Pump gear Gear pump
Type
3. Key (inscription type)
4. Coupling Theoretical delivery
19.6
5. Drive shaft (cc/rev)
6. Plate
7. Charge pump cover
8. Crescent separator plate Function
q This pump is connected to the HST pump drive
Outline shaft (5) with coupling (4). Pumping action is
q This pump is installed on the HST pump. It, turned on as it is rotated.
working in conjunction with the HST pump, q It contains pump gear (2) and crescent separa-
supplies oil to the HST speed-related valve tor plate (8) to suction or delivery oil continu-
and the low-pressure relief valve on the HST ously in the direction shown in the figure.
pump.
WA200-6 13
Speed-related valve (DA valve) 1
1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet
Function
q It diverges the oil from the HST charge pump
into 2 parts. One part flows to the directional
selector solenoid valve and other part flows to
the low-pressure relief valve.
Operation
q Port (A), port (D) and port (C) are connected to
the HST pump charge circuit, low-pressure
relief valve circuit and directional selector sole-
noid valve circuit, respectively.
q The oil from the HST charge pump constantly
flows to the low-pressure relief valve circuit
through port (A), orifice of pilot poppet (5),
chamber (B) and port (D).
q Orifice of pilot poppet (5) applies to the oil
pressure from the HST charge pump. As the
result, the differential pressure is generated in
port (A) and chamber (B).
q Oil pressure in port (A) pushes pilot poppet (5)
in the left direction to flow the oil in chamber
(B) to the directional selector solenoid valve
circuit through port (C).
q A set of pilot poppet (5) is consisted of poppet
spring (3) and spring seat (4).
q When decreasing the set pressure, loosen
locknut (1) and screw adjustment screw (2).
When increasing, loosen the adjustment
screw.
14 WA200-6
High-pressure cutoff valve 1
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
q This valve is installed on the HST pump. If the
oil pressure on the high pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil in the
servo cylinder circuit to the hydraulic tank.
This valve sets the maximum pressure of the
HST pump circuit in this manner to protect the
circuit.
Operation
q Port (A), port (B), port (Pc) and port (T) are
connected to the high pressure circuit in the
reverse travel, high pressure circuit in the for-
ward travel, speed-related valve circuit and
drain circuit, respectively.
q As oil pressure in (A) side goes high, shuttle
spool (7) is pushed down and closes the port
(B) side circuit.
q Oil pressure on port (A) side pushes up piston
(5) and, at the same time, pushes up spool (4),
too, by compressing spring (3).
q Port (Pc) and port (T) are opened, releasing
abnormal pressure generated in port (Pc) to
port (T).
q As oil pressure in port (Pc) goes low, the
swash plate angle of the HST pump is
reduced. As a result, the pump delivery is
reduced and the HST pump circuit is pro-
tected.
WA200-6 15
HST motor 1
a HST: Abbreviation for HydroStatic Transmission

HST motor 1
1. Drive shaft Specifications

2. Piston
Model name A6VM80EP
3. Cylinder block
4. Port plate Type Variable displacement bent
axis type piston motor
5. EP servo valve
Theoretical delivery
(cc/rev) 0 – 80
High-pressure relief valve
(MPa {kg/cm2})
High-pressure cutoff Effective differential pressure
valve set pressure 41.2 {420}
(MPa {kg/cm2})
(MPa {kg/cm2})
16 WA200-6
HST motor 2
1. Drive shaft Specifications

2. Piston
Model name A6VM80HA
3. Cylinder block
4. Port plate Variable displacement bent
Type
axis type piston motor
5. HA servo valve
Theoretical delivery
6. Directional shuttle valve (cc/rev)
46.5 – 80
High-pressure relief valve
(MPa {kg/cm2})
High-pressure cutoff
Effective differential pressure
valve set pressure
41.2 {420}
(MPa {kg/cm })2

(MPa {kg/cm2})
WA200-6 17
Principle Operation
q It is assumed that the shaft of the disc is sup- q Pressurized oil from the HST pump flows to the
ported to enable free rotation of the disc. Force back side of piston (2) through the HST motor
F being applied aslant to the disc is divided inlet port, and is activated by inclination of pis-
into force F1 orthogonal to the disc and force ton (2) and cylinder block (3) as the rotating
F2 that works in the circumferential direction of force of drive shaft (1).
the disc. Force F1 pushes the disc in the axial q As the HST motor is rotated forward or
direction and force F2 rotates the disc clock- reverse, the oil in the high pressure circuit side
wise. is conducted to the directional shuttle valve (6).
q Also when force F' works on the disc instead of q As a large load is applied to the motor being
force F, it is likewise divided into force F1' and connected to servo valve (5), the pressure dif-
F2'. Force F2' rotates the disc counterclock- ference is generated between the high pres-
wise. sure circuit side and directional shuttle valve
(6), allowing the servo cylinder to increase
inclination of cylinder block (3).
Structure
q 7 pistons (2) are installed on the disc portion of
drive shaft (1) like spherical joints. They are
housed in cylinder block (3) having a certain
angle to drive shaft (1).
q As external load to the HST motor is
increased, servo valve (5) and directional shut-
tle valve (6) work to increase inclination of cyl-
inder block (3) and piston (2), reducing the
revolving speed and increasing the torque.
18 WA200-6
EP servo valve 1
1. Motor 1 solenoid valve Operation

2. EP servo valve q Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP
4. Servo cylinder servo valve (2).
q When the current value given to motor 1 sole-
Function noid valve (1) is small (when F1 < F2), EP
q This valve is installed on the rear side of HST servo valve (2) conducts the oil pressure on
motor 1. It controls the motor displacement the motor high pressure side circuit to the
depending on the current value given to motor small diameter side (S) of servo cylinder (4)
1 solenoid valve (1). and releases the oil pressure on the large
diameter side (L) to the tank (motor housing).
As the result, the servo cylinder (4) is moved
toward the min side.
q When the current value given to motor 1 sole-
noid valve (1) is large (when F1 > F2), EP
servo valve (2) conducts the oil pressure to the
large diameter side (L) to move servo cylinder
(4) toward the max side using the difference in
area between the large diameter and small
diameter side (S).
q Magnitude of spring (3) force varies depending
on the position of servo cylinder (4) (motor dis-
placement).
q The current value given to motor 1 solenoid
valve (1) controls the motor displacement to
the position where suction power F1 and
spring force F2 balance.
WA200-6 19
HA servo valve 1
1. Motor 2 solenoid valve Operation

2. HA servo valve q If the load to the motor is small, HA servo valve
3. Servo cylinder (2) conducts oil pressure to the small diameter
side (S) through the directional shuttle valve
Function and releases the oil pressure on the large
q This valve is installed in the rear side of HST diameter side (L) to the tank (motor housing).
motor 2. In order to bring out the motor output Servo cylinder (3) moves toward the min side,
corresponding to the external load to the minimizing the motor displacement.
motor, it controls the motor displacement using q If a large load is applied to the motor during, for
the oil pressure of the circuit being selected instance, uphill travel, HA servo valve (2) is
from the directional shuttle valve. switched to conduct the oil pressure from the
directional shuttle valve to the large diameter
side (L). As a result, the difference in area
between the large diameter side (L) and small
diameter side (S) moves servo cylinder (3)
toward the max side. The motor displacement
becomes the maximum and generates large
torque.
q As motor 2 solenoid valve (1) is energized, HA
servo valve (2) conducts the oil pressure from
the directional shuttle valve to the large diame-
ter side (L) independent of the magnitude of
the load to the motor to set the motor displace-
ment to the maximum.
20 WA200-6
Directional shuttle valve 1
1. Directional selector solenoid valve

2. Directional shuttle valve
Function
q This valve is installed in the rear side of HST
motor 2. It controls the destination of the oil
pressure to work on the HA servo valve refer-
encing the incoming signal, which corresponds
to the directional signal of the directional selec-
tor solenoid valve on the HST pump.
Above process reduces the decelerating
impacts that results when the oil pressure is
switched.
Operation
q Directional selector solenoid valve (1) inter-
locks with the directional selector valve on the
HST pump, since it has received the signal that
is corresponding to the directional signal to be
sent to the directional selector solenoid valve
on the HST pump.
q Directional shuttle valve (2) is activated by
directional selector solenoid valve (1) and con-
trols the destination of the oil pressure to work
on the HA servo valve.
WA200-6 21
Transfer 1
a: Clutch port
b: Lubrication inlet port
c: Lubrication suction port
1. HST motor 2 mounting section

2. HST motor 1 mounting section
3. Oil filler pipe
4. Transfer
5. Parking brake lever
6. Speed sensor
22 WA200-6
1. HST motor 1
2. Input shaft
3. Transfer clutch
4. Carrier
5. Ring gear (number of teeth: 80)
6. Planetary pinion (number of teeth: 24)
7. Planetary shaft
8. Motor 1 gear (number of teeth: 44)
9. Sun gear (number of teeth: 28)
10. Parking brake
11. Rear coupling
12. Output gear (number of teeth: 58)
13. Spacer
14. Output shaft
15. Front coupling
WA200-6 23
Input shaft
Unit: mm
Standard Tolerance Standard Clearance
Clearance between input shaft and size Shaft Hole clearance limit
1 bearing (front) +0.011 0 –0.023 –
50 —
–0.005 –0.012 0.005
Clearance between input shaft 0 +0.013 –0.006 –
2 bearing and cage (front)
80
–0.013 –0.006 0.026
—
Clearance between input shaft and +0.011 0 –0.023 –

3 bearing (middle)
50
–0.005 –0.012 0.005
—

4 bearing and ring gear (middle)
80
–0.013 –0.006 0.026
—
Clearance between input shaft and +0.011 0 –0.023 –

5 bearing (rear)
45
–0.005 –0.012 0.005
—
Replace
6 bearing and carrier (rear)
75
–0.013 –0.006 0.026
—
Clearance between press fitting +0.039 0 –0.054 –

7 shaft and bearing
55
+0.020 –0.015 –0.020
—
Clearance between press fitting 0 –0.016 –0.038 –

8 shaft bearing and motor 1 gear
100
–0.018 –0.038 0.002
—
Clearance between piston and –0.085 +0.040 0.085 –

9 spacer
177
–0.125 0 0.165
—
–0.550 +0.046 0.550 –

10 Clearance between piston and cage 222
–0.650 0 0.696
—
11 Clearance between clutch housing

and front case
200
+0.061
+0.015
+0.046
0
–0.061 –
0.031
—
24 WA200-6
Unit: mm
Standard size Tolerance Repair limit
Thickness of separator plate
12 1.7 ±0.05 1.6
Strain on separator plate — 0.05 0.15
Thickness of friction plate 2.2 ±0.08 1.8

13
Strain on friction plate — 0.02 0.25
14 Load of wave spring

(height: 2.2 mm)
1,010 N
{103 kg}
±101 N
{±10.3 kg}
804 N
{82 kg}
Inside diameter of seal ring contact +0.021
25 25.1
surface 0
+0.15
Width of seal ring groove 2.5 2.7
+0.10
15
–0.01
Width of seal ring 2.5 2.3
–0.03
Thickness of seal ring 1.2 ±0.1 1.05 Replace

70 70.1
surface 0
+0.15
Width of seal ring groove 3 3.3
+0.10
16
–0.01
Width of seal ring 3 2.7
–0.03
Thickness of seal ring 2.9 ±0.1 2.75

120 120.5
surface 0
+0.1
Width of seal ring groove 4.5 5.0
0
17
0
Width of seal ring 4.36 3.9
–0.1
Thickness of seal ring 3 ±0.1 2.7
18 Backlash between sun gear and

planetary pinion
0.078 – 0.252
19 Backlash between planetary pinion

and ring gear
0.100 – 0.407
20 Backlash between motor 1 gear and

output gear
0.170 – 0.453
— Side clearance of planetary gear

(on both sides)
0.35 – 0.80
WA200-6 25
Output shaft
26 WA200-6
Unit: mm
Clearance between output shaft size Shaft Hole clearance limit
1 and bearing (front) +0.030 0 –0.045 –
60 —
+0.011 –0.015 –0.011
Clearance between output shaft 0 –0.015 –0.040 –
2 bearing and cage (front)
110
–0.018 –0.040 0.003
—
Clearance between output shaft +0.030 0 –0.045 –

3 and bearing (rear)
65
+0.011 –0.015 –0.011
—
Clearance between output shaft 0 –0.015 –0.040 –

4 bearing and rear case (rear)
120
–0.018 –0.040 0.003
—
Clearance between oil seal and +0.170 +0.054 –0.170 –

5 cage (front)
100
+0.080 0 –0.026
—
Clearance between dust seal and +0.400 +0.054 –0.400 – Replace

6 cage (front)
100
+0.200 0 –0.146
—
Clearance between oil seal and +0.170 +0.054 –0.170 –

7 cage (rear)
100
+0.080 0 –0.026
—
Clearance between dust seal and +0.400 +0.054 –0.400 –

8 cage (rear)
100
+0.200 0 –0.146
—
Clearance between output shaft 0 +0.030 0–

9 and spacer
60
–0.030 0 0.060
—

10 Inside diameter of coupling oil seal
contact surface (front) 0
75 74.8
–0.074
11 Inside diameter of coupling oil seal

contact surface (rear)
75
0
–0.074
74.8
Standard size Standard clearance Clearance limit

12 Clearance
case
between cage and front
0.7 0.1 – 1.3 —
Adjust with shims
13 Free
shaft
rotational torque of output
3.9 – 5.9 Nm {0.4 – 0.6 kgm}
WA200-6 27
28 WA200-6
1. HST motor 2
2. Motor 2 gear (number of teeth: 44)
3. Strainer
4. Drain plug
Unit: mm
Clearance between input shaft and size Shaft Hole clearance limit
5 bearing +0.030 0 –0.045 –
55 —
+0.011 –0.015 –0.011
Replace
6 bearing and cage
90
–0.015 –0.013 0.037
—
Backlash between motor 2 gear and

7 output gear
0.170 – 0.453
WA200-6 29
Outline Operation of clutch

q The transfer is equipped with 2 HST motors. It
selects a gear speed out of 1st - 4th speed Clutch is "engaged" (fixed)
both in the forward and reverse travels and
transmits it to the output shaft. It changes the
gear speed by varying output and revolving
direction of the HST motors and combinations
of the transfer clutches.
Relation between transfer clutch and transfer

clutch pressure at respective speed ranges
Speed
Transfer clutch Transfer clutch pressure
range
1st Engaged OFF
2nd Engaged OFF
Travel Travel Travel Travel
speed speed speed speed q As the oil from the clutch solenoid valve is cut
3rd 0 – A km/h A – 20 km/h 0 – A km/h A – 20 km/h off, piston (2) is pushed back in the right direc-
Engaged Disengaged OFF ON tion by the repulsive force of spring (1).
Travel Travel Travel Travel q Piston (2) compresses plates (3) and discs (4)
speed speed speed speed and the rotation of discs (4) is stopped by the
4th 0 – A km/h A – 34.5 km/h 0 – A km/h A – 34.5 km/h
frictional force.
Engaged Disengaged OFF ON q As the internal teeth of disc (4) are meshed
*1: The travel speeds listed above are the ones when the with the external teeth of ring gear (5), ring
tires of the size 17.5-25 are worn. And value A varies gear (5) is fixed.
depending on the opening ratio of the accelerator pedal.
Clutch is "disengaged" (released)

Relationship between accelerator pedal angle
and travel speed (A) for starting transfer clutch
switching modulation
Accelerator pedal angle (%)
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o 8 km/h 8 – 10 km/h 10 km/h
Disengaged (B)
Disengaged o
7 km/h 7 – 9 km/h 9 km/h
Engaged (C)
q The oil from the clutch solenoid valve is pres-

sure-fed to the back side of piston (2), and
pushes piston (2) in the left direction by com-
pressing spring (1).
q Plates (3) and discs (4) are released from the
frictional force, setting ring gear (5) to the neu-
tral position.
q Wave spring (6) is assembled between plates
(3) to accelerate return of piston (2) as the
clutches are released. And at the same time, it
helps smooth separation of plates (3) and
discs (4) in order to prevent drag turning.
30 WA200-6
Power transmitting route

Low speed mode
Transfer clutch (1) is fixed to transmit power of both HST motor 1 (2) and HST motor 2 (3).
Power of HST motor 1 (2) Power of HST motor 2 (3)

O O
Input shaft (4) O
O O
Sun gear (5) O
O O
Planetary pinion (6) O
O O
Carrier (7) O
O O
Motor 1 gear (8) Motor 2 gear (9)
O O
Output gear (10) i i
O
Output shaft (11)
WA200-6 31
High speed mode
Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone.
Power of HST motor 2 (3)

O
Motor 2 gear (9)
O
Output gear (10)
O
Output shaft (11)
32 WA200-6
Clutch solenoid valve 1
P: From HST charge pump Operation

A: To transfer clutch q When the current value of input signal is large,
T: To drain the transfer clutch drains oil pressure.
q As the current value of input signal becomes
1. Clutch solenoid valve smaller, oil pressure of the transfer clutch goes
2. Plunger higher inversely proportional to the current
3. Coil value.
4. Push pin q If the current value of input signal is further
5. Spring lowered until the oil pressure of the transfer
6. Spool clutch reaches the oil pressure at which oil is
7. Body pressure-fed from the HST charge pump, the
oil pressure of the transfer clutch remains at
this level even if the current value may be fur-
ther decreased.
WA200-6 33
Axle 1
Front axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Oil temperature sensor
34 WA200-6
Rear axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
WA200-6 35
Differential 1
Front differential 1
1. Pinion (number of teeth: 9)

2. Shaft
3. Bevel gear (number of teeth: 43)
4. Sun gear shaft
5. Bevel pinion (number of teeth: 12)
6. Side gear (number of teeth: 12)
36 WA200-6
Unit: mm
7 Starting torque of bevel gear 88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear) Adjust

8 Thickness of pinion washer
3 ±0.08 2.8
Replace
9 Thickness of side gear washer 2 ±0.05 1.8
10 Thickness of shim in differential

side bearing carrier (one side)
0.50 – 1.35
Adjust
11 Backlash of bevel gear 0.20 – 0.33
12 End play of pinion

(or starting torque)
0 – 0.162
(0 – 61 N {0 – 6.2 kg} (at cage blot hole))
Replace

housing and cage assembly
0.50 – 1.23 Adjust

size Shaft Hole clearance limit
14 Clearance of differential
side bearing Outer race 112.713
+0.025 –0.004 –0.054 –
—
0 –0.029 –0.004
+0.066 +0.013 –0.066 –
Inner race 69.85 —
+0.045 0 –0.032
0 –0.048 –0.088 –
Outer race 130 —
–0.018 –0.088 –0.030
15 Clearance of bearing on
pinion shaft gear side +0.039 0 –0.054 –
Inner race 60 —
+0.020 –0.015 –0.020
0 –0.041 –0.076 –
Clearance of bearing on Outer race 120
–0.015 –0.076 –0.026
—
16 pinion shaft coupling
side +0.039 0 –0.054 – Replace
Inner race 55 —
+0.020 –0.015 –0.020
17 Clearance
spider
between pinion gear and
28
–0.06
–0.11
+0.10
+0.05
0.11 –
0.21
—
Clearance in installation position of

–0.110 +0.081 0.110 –
18 differential housing piston 261
–0.191 0 0.272
—
(between housing and piston)
–0.100 +0.072 0.100 –
19 bearing carrier piston 241
–0.172 0 0.244
—
(between piston and carrier)
0 0 –0.035 –
Clearance between Outer race 110 —
–0.015 –0.035 0.015
20 drive shaft and cage
bearing +0.021 0 +0.002 –
Inner race 50 —
+0.002 –0.012 +0.033
WA200-6 37
Rear differential 1

2. Shaft
4. Sun gear shaft
5. Bevel pinion (number of teeth: 12)
38 WA200-6
Unit: mm
7 Starting torque of bevel gear 88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear) Adjust

8 Thickness of pinion washer
3 ±0.08 2.8
Replace
9 Thickness of side gear washer 2 ±0.05 1.8

side bearing carrier (one side)
0.50 – 1.35
Adjust
11 Backlash of bevel gear 0.20 – 0.33
12 End play of pinion

(or starting torque)
0 – 0.162
(0 – 61 N {0 – 6.2 kg} (at cage blot hole))
Replace

housing and cage assembly
0.50 – 1.23 Adjust

14 Clearance of differential
side bearing Outer race 112.713
0 –0.004 –0.029 –
—
–0.018 –0.029 0.014
+0.066 0 –0.081 –
Inner race 69.85 —
+0.045 –0.015 –0.045
0 –0.023 –0.063 –
Outer race 130 —
–0.018 –0.063 –0.005
15 Clearance of bearing on
pinion shaft gear side +0.039 0 –0.054 –
Inner race 60 —
+0.020 –0.015 –0.020
0 –0.041 –0.076 – Replace
Clearance of bearing on Outer race 120
–0.015 –0.076 –0.026
—
16 pinion shaft coupling
side +0.039 0 –0.054 –
Inner race 55 —
+0.020 –0.015 –0.020
17 Clearance
spider
between pinion gear and
25.18
–0.13
–0.18
+0.10
+0.05
0.180 –
0.280
—

–0.110 +0.081 0.110 –
18 differential housing piston 261
–0.191 0 0.272
—
(between housing and piston)
–0.100 +0.072 0.100 –
19 bearing carrier piston 241
–0.172 0 0.244
—
(between piston and carrier)
WA200-6 39
Outline While machine is traveling straight
q The power from the engine is transmitted to

the front and rear axles through the torque
converter, transmission and drive shaft.
q In each axle, the direction of the power is q While the machine is traveling straight, the
changed by 90° and the speed is reduced by right and left wheels rotate at the same speed.
bevel pinion (1) and bevel gear (5). Then, the Accordingly, pinion (4) in the differential
power is transmitted through pinion (4) to sun assembly does not rotate and the power of car-
gear shafts (2). rier (6) is transmitted through pinion (4) and
q Speed of the power transmitted to the sun gear side gear (3) to right and left sun gear shafts
is further reduced by the final drive of the plan- (2) evenly.
etary gear type, and then transmitted to the
axle shafts and wheels. While machine is turning
q While the machine is turning, the right and left

wheels rotate at different speeds. Accordingly,
pinion (4) and side gear (3) in the differential
rotate and transmit the power of carrier (6) to
sun gear shafts (2), depending on the differ-
ence in rotation speed between the right and
left wheels.
40 WA200-6
Torque proportioning differential 1
Outline Operation
Straight travel (When the road resistances
under both tires are the same)
q When the road resistances under the both tires

are the same, distance (a) from pinion (4) to
the meshing point of left side gear (7) and dis-
tance (b) to the meshing point of right side
gear (3) are the same.
q Accordingly, left traction force (TL) and right
traction force (TR) are balanced.
Travel on soft ground (When the road resis-

tances under both tires are different)
q A 4-wheel-drive wheel loader, as a construc-

tion machine, must naturally work on places
where the ground condition is bad. If its tires
slip in such places, its function lowers and the
lives of the tires are shortened. To solve this
problem, the torque proportioning differential is
used.
q Pinion (4) of this differential has an odd num-
ber of teeth. The meshing points of pinion (4)
and side gears (3) change according to the dif-
ference of the road resistance. Consequently,
the traction forces of the tires on both sides q When the tires slip on soft ground, the side
change. gear of the tire on the less road resistance side
turns forward. As a result, the meshing points
of pinion (4) and the side gears change.
q If left side gear (7) turns forward a little, dis-
tance (a) from the pinion to the meshing point
of the left side gear becomes longer than dis-
tance (b) to the meshing point of the right side
gear, and then (a) and (b) are balanced at a
point where (a) x (TL) = (b) x (TR). The ratio of
(a) : (b) changes up to 1 : 1.38, depending on
the meshing condition.
WA200-6 41
q Accordingly, the pinion does not run idle and

the drive force is transmitted to both side gears
and the tires do not slip until the ratio of (a) : (b)
becomes 1 : 1.38, or the difference between
the road resistances under both tires becomes
38%.
q The lives of the tires are lengthened 20 - 30%
and the working capacity is increased by the
above effect.
42 WA200-6
WA200-6 43
Limited slip differential 1
(if equipped)
1. Plate
2. Disc
4. Washer
6. Bevel pinion
7. Shaft
8. Pressure ring
10. Case
44 WA200-6
Unit: mm
3
11 Thickness of plate
±0.02 2.9
3.1
+0.04
12 Thickness of disc 2.5
–0.03
2.45
13 Thicknesses of washer 2 ±0.05 1.8
14 Clearance between disc and plate

(total clearance on both sides)
0.2 – 0.6
Replace
15 End play of side gear in axial
direction (one side)
0.13 – 0.36
16 Backlash of case and plate 0 – 0.5
17 Backlash of side gear and disc 0.13 – 0.32

18 Clearance between spider and
differential pinion –0.110 +0.05 0.110 –
25.4 —
–0.160 0 0.210
WA200-6 45
Operation of limited slip differential While machine is traveling straight

q The power from the transmission is transmitted When the drive forces of the right and left
through bevel gear (9), case (10), pressure wheels are balanced
ring (8), shaft (7), pinion (3) and side gear (5), [When the road conditions (coefficient of friction)
and then divided to the right and left shafts. under both wheels and the wheel loads are even,
q The brake unit consisting of disc (2) and plate and the center of load is at the center of the bucket]
(1) is installed to the back side of side gear (5).
It generates braking torque in proportion to the
torque transmitted from pressure ring (8) to
shaft (7).
q Since the brake torque restricts the rotation of
side gears (5) and case (10), right and left side
gears (5) cannot rotate freely. Thus, the opera-
tion of the differential is restricted.
Mechanism of generation of braking torque by

right and left side gears (5)
q Shaft (7) is supported on the cam surfaces

being provided on the surfaces of pressure
rings (8) that are facing each other.
q The power (= torque) transmitted from pres-
sure rings (8) to shaft (7) is transmitted on the q The power from the transmission is distributed
cam surfaces. Force (Fa) to separate pressure evenly by the differential gears to the right and
rings (8) from each other is generated by incli- left. Under this condition, the slip limits of the
nation of the cam surfaces in proportion to the right and left wheels are the same. Accord-
transmitted torque. ingly, even if the power from the transmission
q Separating load (Fa) acts on the brake on the may exceed the slip limits, both wheels slip
back side of each side gear (5) to generate and the differential does not work.
braking torque. No load is applied to the brake on the back
side of the side gear.
46 WA200-6
When the drive forces of the right and left Difference in wheel drive force by type of differen-
wheels are unbalanced tials when either wheel slipped
[When the road conditions (coefficient of friction) Wheel drive force
under both wheels and the wheel loads are uneven, (drive force of slipping wheel is 1)
and either wheel slips more easily] Slipping wheel Locked wheel Total (ratio)
Example 1. When either wheel is on soft ground
Limited slip
in digging work differential 1 2.64 3.64 (1.53)
Example 2. When either wheel is on snow and (if equipped)
the other one is on asphalt in snow Torque
removing work proportioning
1 1.38 2.38 (1)
Example 3. When the right and left wheel loads differential
are unbalanced in travel on a slope (standard)
Conventional
1 1 2 (0.84)
differential
Torque proportioning differential

q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.53 times of the torque propor-
tioning differential.
Conventional differential
(this is not applied with this machine.)
q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.82 times of the conventional dif-
ferential.
While machine is turning
q The power from the transmission is evenly

divided between the right and left by the differ-
ential gear. If, however, the divided drive force q The same gears as that for the conventional
exceeds the wheel slip limit of the slip side, differential are employed for the limited slip dif-
surplus of the driving force is transmitted to the ferential. Thus, they allow to smoothly gener-
opposite side (lock side) brake through the ate a difference in rotation speed between the
brake and case on the gear back side. Then outer and inner wheels that is necessary for
the power is distributed to the lock side wheel. tuning.
q The differential starts working only as the sur-
plus portion of the drive force has exceeded
the braking force.
WA200-6 47
Final drive 1
Front final drive 1
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
5. Sun gear shaft (number of teeth: 15)
48 WA200-6
Rear final drive 1
1. Planetary gear (number of teeth: 26)

3. Axle shaft
5. Sun gear shaft (number of teeth: 15)
WA200-6 49
Unit: mm
Clearance between planetary gear size Shaft Hole clearance limit
6 bearing and shaft +0.025 +0.013 –0.025 – Replace
33.338 —
+0.013 0 0
Clearance between axle housing +0.100 +0.100 –0.100 –
7 and ring gear
276
+0.030 0 +0.070
—
Clearance between oil seal and

8 housing
Max. 0.2 Adjust
+0.400 +0.063 –0.400 –

Housing 140 —
Press fitting part of axle +0.200 0 –0.137
9 shaft seal 0 –0.200 –0.400 –
Shaft 105 —
–0.054 –0.400 –0.146
0 –0.028 –0.068 –
Clearance of press Outer race 130 —
–0.025 –0.068 –0.003
10 fitting part of axle Replace
housing bearing +0.045 0 –0.065 –
Inner race 85 —
+0.023 –0.020 –0.023
0 –0.028 –0.068 –
Clearance of press Outer race 125 —
–0.018 –0.068 –0.010
11 fitting part of axle
housing bearing +0.030 0 –0.045 –
Inner race 80 —
+0.011 –0.015 –0.011
12 End play of axle shaft 0 – 0.1 Adjust
+0.025 +0.207 0.120 –

13 Clearance of guide pin 12
+0.007 +0.145 0.200
— Replace
a Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and
assembly.
50 WA200-6
Outline
a The figure shows the front axle.

q The final drive finally reduces speed of the
power from the engine to increase the drive
force.
q Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
q Speed of the power being transmitted from the
differential through sun gear shaft (5) is
reduced by the planetary gear unit to increase
the drive force.
The increased drive force is transmitted
through planetary carrier (2) and axle shaft (3)
to the tire.
WA200-6 51
SEN03251-00

©2007 KOMATSU
All Rights Reserved
52
SEN03252-00
WA200-6
WA200-6 70001 and up

Steering system
Steering piping diagram .................................................................................................................................. 3
Steering column .............................................................................................................................................. 4
Priority valve ................................................................................................................................................... 5
Orbit-roll valve................................................................................................................................................. 8
2-way restrictor valve .................................................................................................................................... 16
Cushion valve ............................................................................................................................................... 17
Steering cylinder ........................................................................................................................................... 18
Emergency steering piping diagram ............................................................................................................. 20
Emergency steering valve............................................................................................................................. 21
Steering relief valve....................................................................................................................................... 24
WA200-6 1
2 WA200-6
Steering piping diagram 1
1. Steering cylinder (right)

2. Orbit-roll valve
3. Hydraulic tank
4. Priority valve
5. Steering pump
6. 2-way restrictor valve
7. Cushion valve
8. Steering cylinder (left)
WA200-6 3
Steering column 1
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Tilt lever
Unit: mm
Clearance between steering shaft size Shaft Hole clearance limit
5 and column bushing
Replace
0 +0.15 0.05 –
19 0.4
–0.08 +0.05 0.23
4 WA200-6
Priority valve 1
P: From steering pump LS: From Orbit-roll valve

CF: To Orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve
1. Relief valve body 7. Plug

2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen
Unit: mm
Installed Installed
Free length Free length Installed load
12 Control spring length load
187 N 187 ± 14.7 N Replace
63.4 47.6 63.4 ± 1
{19.1 kg} {19.1 ± 1.5 kg}
132 N 132 ± 14.7 N
13 Relief spring 31 27.3
{13.3 kg}
—
{13.3 ± 1.5 kg}
WA200-6 5
Outline Operation
q The priority valve is installed between the
steering pump and Orbit-roll valve and work When steering wheel is at "neutral" position
equipment control valve. It diverges the oil
from the steering pump to the steering circuit
or work equipment circuit. It is also used for
controlling the oil pressure from the priority
valve to the Orbit-roll valve in order to protect
the circuit.
Set pressure: 18.6 MPa {190 kg/cm2}
q When the engine is stopped, spool (3) is

pushed in the left direction by the repulsive
force of spring (4). Thus, port (M) and port (N)
are fully opened and port (M) and port (Q) are
closed.
q Starting the engine starts the steering pump
rotation, and the oil from the pump flows to port
(A) of the Orbit-roll valve through port (M) and
port (N).
q The oil that flew to chamber (P) through orifice
(m) of spool (3) pushes spool (3) in the right
direction by compressing spring (4).
q Port (M) and port (Q) are opened and port (M)
and port (N) are almost closed to stabilize
spool (3).
q Most of the oil from the pump flows to the work
equipment circuit through port (Q).
6 WA200-6
When steering wheel is "turned left" When steering cylinder is at stroke end
q Turning the steering wheel left changes the q Trying to continuously turn the steering wheel
angle between the sleeve and spool on the after the steering cylinder has reached the
Orbit-roll valve, switching flow of the oil. (see stroke end increases oil pressure in port (S).
"Orbit-roll valve".) q As the oil pressure in port (S) goes beyond the
q Part of the oil from the pump that has flown to set pressure of relief valve (10), the relief valve
port (A) is then conducted to the R.H. steering (10) releases the oil pressure in port (S) to the
cylinder through port (B) and Gerotor, and the hydraulic tank through port (T).
remaining portion of the oil flows to chamber q It generates differential pressure before and
(R) through orifice (b) and port (J). after orifice (r), breaking down the balance
q Change in the angle between the sleeve and between the difference pressure up to port (A)
spool on the Orbit-roll valve generates a differ- and after port (B) and the repulsive force of
ence pressure between the oil pressure up to spring (4). As a result, oil pressure up to port
port (A) and that after port (B). (A) becomes relatively higher.
q Spool (3) stabilizes at a position where the dif- q As port (A) oil pressure is increased, oil in
ference pressure between that of up to port (A) chamber (P) pushes spool (3) in the right direc-
and after port (B) [chamber (P) pressure - tion by compressing spring (4).
chamber (R) pressure] is balanced with the q Port (M) and port (N) are almost closed, and
repulsive force of spring (4). port (M) and port (N) are nearly fully opened to
q The ratio of diversion is determined by the dis- stabilize spool (3).
placement in angle between the spool and
sleeve on the Orbit-roll valve, namely the
opening ratio of port (A) and port (B). And
changing the operating distance of the steering
wheel enables its stepless adjustment.
WA200-6 7
Orbit-roll valve 1
P: From steering pump LS: To priority valve

L: To steering cylinder T: To hydraulic tank
R: To steering cylinder
1. Gland
2. Valve body
3. Check valve
4. Gerotor
5. Spacer
6. Cover
7. Spacer
8. Drive shaft
9. Sleeve
10. Spool
11. Center pin
12. Centering spring
13. Anti-cavitation valve
14. Overload relief valve
8 WA200-6
Outline Structure
q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the steering pump to the right or left nected to sleeve (8) through center pin (7)
steering cylinder to decide the travel direction (which is not in contact with spool (9) while the
of the machine. steering wheel is at "neutral") and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) that have rotary type q Top (B) of drive shaft (3) is engaged with cen-
direction selecting function and Gerotor (5) ter pin (7) and united with sleeve (8) and the
(combination of rotor (5a) and stator (5b)) that bottom is engaged with the spline of rotor (5a)
operates as a hydraulic motor during the nor- of the Gerotor (5).
mal steering operation and as a hand pump q 4 ports are provided on valve body (4). Each
(the steering wheel's operating effort becomes port is respectively connected to the pump cir-
too high to operate it actually) when the oil is cuit, tank circuit, L.H. steering circuit and R.H.
not supplied because of a trouble of the steer- steering circuit. And the ports of the pump side
ing pump or engine. and tank side are connected by the check
valve in the body. If the pump or engine fails,
the oil can be sucked through this check valve
directly from the tank side.
WA200-6 9
Operation
When steering wheel is at "neutral" position
10 WA200-6
q When the steering wheel is at "neutral" posi-

tion, centering spring (2) sets center pin (7) to
the center of the oblong hole on spool (9) and
move of spool (9) and sleeve (8) is stopped.
q Port (A) from sleeve (8) pump, port (E) to the
Gerotor, port (F) to the R.H. steering circuit and
port (G) to the L.H. steering circuit cut off the
vertical grooves (B), (C) and (D) on spool (9).
q Orifice (b) of port (J) to the priority valve is con-
nected to vertical groove (B) on spool (9).
q Port (K) of sleeve (8) is connected to vertical
groove (M) and port (L) on spool (9).
q Due to connection and disconnection of the
ports and vertical grooves, the oil in the priority
valve being set to the pilot pressure is con-
ducted through port (J), orifice (b), vertical
groove (M) and port (K), then drained from port
(L) to the hydraulic tank.
WA200-6 11
When steering wheel is "turned left"
12 WA200-6
q As the steering wheel is "turned left", spool (9) When steering wheel is at "stop" position
being connected to the drive shaft of the steer- q As operation of the steering wheel is stopped,
ing column is rotated counterclockwise. angular displacement between spool (9) and
q Since spool (9) and sleeve (8) are connected sleeve (8) disappears and the steering wheel
by centering spring(2), spool (9) compresses is returned to the neutral position by the repul-
centering spring (2). sive force of centering spring (2).
q An angular displacement corresponding to the
amount of compression of centering spring (2)
is generated between spool (9) and sleeve (8).
q Port (A) and vertical groove (B) are connected
first being followed by the connection between
vertical groove (B) and port (E), port (E) and
vertical groove (C), and vertical groove (C) and
port (G) to the L.H. steering circuit.
q Although the connection between vertical
groove (B) and orifice (b) of port (J) to the pri-
ority valve is maintained, port (K) of sleeve (8)
starts gradually closing vertical groove (M) and
port (L).
q Port (F) of the R.H. steering circuit is con-
nected to vertical groove (D) at the same time
as port (A) and vertical groove (B) are con-
nected.
q Due to connection and disconnection of the
ports and vertical grooves, the oil from the
pump flows from port (A) to vertical groove (B)
then flows to port (E), starting rotation of the
Gerotor. The oil discharged from the Gerotor
flows to the L.H. steering cylinder head side
through port (E), vertical groove (C) and port
(G).
q Oil pressure of vertical groove (M) is transmit-
ted to port (J) through orifice (b), then supplied
from port (J) as the pilot pressure of the priority
valve.
q The oil from the R.H. steering cylinder head is
drained to the hydraulic tank through port (F),
vertical groove (D) and port (H).
WA200-6 13
Connection of hand pump and sleeve
q Above figure shows the suction and discharge q The internal gear of the Gerotor advances by 1
ports (P) of the Gerotor and connections with tooth with every 1/7 turn of the steering wheel
the sleeve ports. and discharges the oil from the pump accord-
q If the steering wheel is turned to the right, ports ing to the steering angle of the steering wheel.
(a), (c), (e), (g), (i), and (k) will be connected to Accordingly, the discharge amount varies in
the pump side by the vertical grooves of the proportion to the steering angle of the steering
spool. Likewise, ports (b), (d), (f), (h), (j), and (l) wheel.
are connected to the R.H. steering cylinder
head side.
Under the condition in Fig. 1, ports (1), (2) and
(3) are in the discharge state of the Gerotor
and connected to ports (l), (b), and (d) and the
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil form the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90° continued for
above condition. Under this state, ports (2), (3),
and (4) are in the suction state and connected
to ports (k), (a), and (c). Ports (5), (6), and (7)
are in the discharge state and connected to
ports (d), (f), and (h).
q As shown above, the ports in the discharge
state of the Gerotor are connected to the ports
being connected to the steering cylinder. The
ports in the suction state are connected to the
pump circuit.
14 WA200-6
Role of centering spring
q Centering spring (2) is composed of 4 X-

shaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is generated between spool (9)
and sleeve (8).
As a result, the ports of spool (9) and sleeve
(8) are connected and the oil is sent to the
steering cylinder. When the steering wheel
stops turning, the Gerotor also stops turning.
Then, the oil is not sent to the steering cylinder
any more and its pressure rises.
To prevent this, when the steering wheel
stopped turning, Gerotor is turned by the reac-
tion force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) to
return the steering wheel to the "neutral" posi-
tion.
WA200-6 15
2-way restrictor valve 1
1. Tube
2. Poppet
3. Body
Function
q In order to buffer the impacts resulting from the
momentum of the machine when switching the
steering, an orifice installed in the circuit near
to the cylinder controls the move of the cylinder
piston by giving pressure to the return oil.
Operation
q When flowing in the left direction (in the cylin- q When flowing in the right direction (to the cylin-
der's forward move direction), the oil pushes der's return direction), the oil conducted
open poppet (3), and flows from orifice (a) and through orifice (a) of poppet (3) alone, thus the
notch (b) of poppet (3). flow rate is restricted.
16 WA200-6
Cushion valve 1
A: From steering cylinder left turning port Outline

B: From steering cylinder right turning port q If sudden increase or bouncing occurs in oil
pressure of the steering cylinder circuit, this
1. Valve seat valve mitigates the impacts by releasing the
2. Valve body highly pressurized oil to instantly to other line.
3. Spring
4. Poppet Function
5. Orifice q As highly pressurized oil rushed into port (A), it
6. Plug compresses spring (3) and opens poppet (4) of
7. Spring port (A) side, then flows through the center
8. Spool groove of spool (8) up to port (B) opening pop-
9. Plug pet (11) of port (B) side.
10. Spring q At the same time, the highly pressurized oil
11. Poppet flows to the pressure chamber of plug (6)
through orifice (5) of port (A) side. Then over-
coming the port (B) side pressure and repul-
sive force of spring (7), it pushes spool (8) in
the right direction, cutting off the flow of oil from
port (A) to port (B).
q Temporary flow of oil to the cushion valve
works as cushioning effects in mitigating the
steering impacts. After the operation of the
cushion valve is completed, the steering func-
tions as usual.
q If the pressure change on the steering cylinder
circuit is gradual, spool (8) cuts off the circuit
before poppet (4) opens. Thus, the cushion
valve remains inactivated.
WA200-6 17
Steering cylinder 1
Unit: mm
Clearance between bushing in size clearance limit
Shaft Hole
1 cylinder rod frame connecting part
and mounting pin 0 +0.180 0.042 –
40 —
–0.025 +0.042 0.205
Clearance between bushing in
0 +0.180 0.042 –
2 cylinder bottom frame connecting 40
–0.025 +0.042 0.205
—
Replace
part and mounting pin
Width of boss Width of hinge Standard (a + b) clearance
Connecting part of steering cylinder
3 and front frame Max. 0.5
50 53
(after shim is adjusted)
Connecting part of steering cylinder Max. 0.5
4 and rear frame
50 53
(after shim is adjusted)
18 WA200-6
Unit: mm
Clearance between piston rod and size Shaft Hole clearance limit
1 bushing –0.025 +0.132 0.031 –
40 0.496
–0.064 +0.006 0.196 Replace pin and
Clearance between piston rod 0 +0.180 0.042 – bushing
2 supporting shaft and bushing
40
–0.025 +0.042 0.205
1.0
Clearance between cylinder bottom 0 +0.180 0.042 –

3 supporting shaft and bushing
40
–0.025 +0.042 0.205
1.0
WA200-6 19
Emergency steering piping diagram 1
(if equipped)
1. Steering pump
2. Priority valve
3. Orbit-roll valve
4. Check valve
5. Emergency steering valve
6. HST motor 2
7. Pressure switch (for detecting emergency steering operation)
8. Steering relief valve
9. Pressure switch (for detecting low oil pressure on steering)
20 WA200-6
Emergency steering valve 1
(if equipped)
PP: From steering pump 1. Check valve body

A: To HST motor 2 port A 2. Check valve
B: To HST motor 2 port B 3. Valve body
Y: To Orbit-roll valve 4. Pressure reducing valve
S: From hydraulic tank 5. Selector valve
G: To pressure switch
WA200-6 21
Operation
When engine and steering pump are normal
q As long as the engine and steering pump are

operating normally, the oil being pressure-fed
from the steering pump flows to the Orbit-roll
valve, enabling the steering.
q The oil from the steering pump flows to port
(PP), pushes spool (1) in the left direction, then
cuts off the circuit from the HST motor to the
Orbit-roll valve.
22 WA200-6
When engine or steering pump is abnormal
q If, during travel, the steering pump fails to sup-

ply sufficient amount of oil to the Orbit-roll
valve due to a trouble on the engine or steering
pump, discharge pressure of the steering
pump goes low. As a result, spool (1) is
pushed back in the right direction by the repul-
sive force of spring (2).
q The high pressure side is selected for the oil
from the HST pump at check valves (3) and
(4), and the oil pressure is decreased to an
appropriate level at pressure reducing valve
(5).
q De-pressurized oil flows through port (Y) to the
Orbit-roll valve, enabling the steering.
q If the oil in the HST circuit goes low because of
flowing out to the steering circuit, oil is supplied
to the HST circuit by check valves (6) and (7).
a Thanks to the function of check valves (3) and

(4), the emergency steering system is operable
both in the forward and reverse travel.
WA200-6 23
Steering relief valve 1
(if equipped)
P1: From steering pump Outline

P2: From emergency steering pump q The steering relief valve is installed to the right
T: Drain side of the transmission and used to hold the
S1: Steering pump oil pressure switch (Low) steering oil pressure to the set pressure.
S2: Steering pump oil pressure switch (Hi) Set pressure: 1.96 MPa {20 kg/cm2}
S3: Emergency steering oil pressure switch (cracking pressure at 0.5 l/min)
1. Block
2. Relief valve
3. Orifice
24 WA200-6
WA200-6 25
SEN03252-00

©2007 KOMATSU
All Rights Reserved
26
SEN03253-00
WA200-6
WA200-6 70001 and up

Brake system
Brake piping diagram ...................................................................................................................................... 3
Charge valve................................................................................................................................................... 4
Brake valve ..................................................................................................................................................... 8
Inching valve ................................................................................................................................................. 12
Accumulator (for brake) ................................................................................................................................ 13
Slack adjuster ............................................................................................................................................... 14
Brake............................................................................................................................................................. 16
Parking brake control .................................................................................................................................... 21
Parking brake................................................................................................................................................ 22
WA200-6 1
2 WA200-6
Brake piping diagram 1
1. Hydraulic tank 8. Strainer

2. Brake valve 9. Slack adjuster (for front left side)
3. Brake and cooling fan pump 10. Front brake
4. Rear brake 11. Slack adjuster (for front right side)
5. Accumulator (for front side) 12. Slack adjuster (for rear right side)
6. Accumulator (for rear side) 13. Slack adjuster (for rear left side)
7. Charge valve
WA200-6 3
Charge valve 1
4 WA200-6
P: From brake and cooling fan pump

T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (rear side)
ACC2: To accumulator (front side)
S: Brake operation sensor port
G: Gauge port
1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Unload valve
6. Relief valve
Unit: mm
Clearance between inverse shuttle size Shaft Hole clearance limit
7 valve and body –0.006 +0.011 0.006 –
12 0.029
–0.014 0 0.025
Clearance between plunger and –0.005 +0.009 0.005 –
8 body
8
–0.012 0 0.021
0.024
Clearance between unload valve –0.006 +0.011 0.006 –

9 and body
18
–0.017 0 0.028
0.032

Installed Installed Installed
Free length Free length Replace
10 Inverse shuttle valve return spring length load load
9.8 N 8.3 N
21.6 18.3 —
{1.0 kg} {0.85 kg}
11 Unload
(inside)
relief valve return spring
35.9 30.0
188 N
{19.2 kg}
—
160 N
{16.3 kg}
12 Unload relief valve return spring

(outside)
39.8 27.5
137 N
{14.0 kg}
—
116 N
{11.8 kg}
49 N 42 N
13 Unload valve return spring 51.6 45.0
{5.0 kg}
—
{4.3 kg}
4.9 N 4.2 N
14 Check valve return spring 11.5 9.0
{0.5 kg}
—
{0.43 kg}
Function
q The charge valve maintains the oil pressure
from the pump to the set pressure and accu-
mulates it in the accumulator.
q If the oil pressure from the pump goes beyond
the relief valve s et pres sur e, this valve
releases the oil pressure to the drain circuit in
order to reduce the load to the pump.
WA200-6 5
Operation
When oil is not supplied to accumulator When oil is supplied to accumulator
(cut-out state) 1. Cut-in state
q Plunger (1) is moved in the left direction by the q As the accumulator pressure goes low, pres-
accumulator pressure, and maintains unload sure on port (E) goes low, allowing plunger (1)
relief valve (2) being pushed open. to move in the right direction and unload relief
q The oil in the spring chamber of unload valve valve (2) to close the drain circuit.
(3) is drained to the hydraulic tank through port q Since the oil pressure in port (F) and the spring
(F), unload relief valve (2) and port (T). chamber of unload valve (3) increases, unload
q Since oil pressure in port (F) is decreased, valve (3) moves in the right direction.
unload valve (3) moves in the left direction q Port (C) and port (B) are opened, conducting
being subjected to the action of the oil from the oil from the pump to port (B).
chamber (B). q As oil pressure in port (B) increases beyond
q Port (C) and port (D) are opened, supplying the set pressure of check valve (4), check
most of the oil from the pump to the cooling fan valve opens, allowing the oil to be supplied to
motor through port (P), ports (C) and (D), and the accumulator through port (E). The pressure
port (A). for supplying oil to the accumulator depends
on the set pressure of check valve (4).
q Amount of oil supplied to the accumulator is
constant independent of the engine speed,
thus surplus of the oil flows to the cooling fan
motor through port (A).
q Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.
6 WA200-6
When the oil pressure from the pump went

2. When pressure reaches cut-out pressure beyond the set pressure
q As pressure in port (F) reaches the set pres- q As oil pressure in chamber (B) reaches the set
sure (cut-out pressure of unload relief valve pressure of relief valve (6), relief valve (6) is
(2)), oil in the spring chamber of unload valve opened to drain the oil from the pump to the
(3) is drained to the hydraulic tank through port hydraulic tank through port (T).
(F), unload relief valve (2) and port (T). Above process protects the brake circuit by
q Plunger (1) is moved in the left direction by the restricting its maximum pressure.
accumulator pressure, and maintains unload
relief valve (2) being pushed open.
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the left direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).
WA200-6 7
Brake valve 1
P1: From HST pump A: To Rear brake

T1: To hydraulic tank PB: From accumulator (front side)
T2: To steering pump (suction side) B: To front brake
PA: From accumulator (rear side)
1. Rod 5. Brake valve body (for rear)

2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm
Clearance between inching valve size Shaft Hole clearance limit
8 spool and body –0.022 +0.033 0.020 –
22.4 0.096
–0.053 0 0.086
Clearance between inching valve –0.022 +0.033 0.020 –
9 guide and body
22.4
–0.053 0 0.086
0.096
10 Clearance between inching valve

spool and guide
12
–0.050
–0.093
+0.050
0
0.050 –
0.143
0.157

Installed Installed Installed Replace
Free length Free length
11 Inching valve control spring length load load
24.5 N 20.8 N
34.7 16.7 —
{2.5 kg} {2.1 kg}
113 N 96 N
12 Brake valve control spring 35.6 24.0
{11.5 kg}
—
{9.8 kg}
19.6 N 16.7 N
13 Inching valve return spring 50.0 49.5
{2.0 kg}
—
{1.7 kg}
147 N 125 N
14 Brake valve return spring 114.9 52.4
{15.0 kg}
—
{12.7 kg}
8 WA200-6
Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q The brake valve contains the inching valve to
regulate the control pressure of the HST pump.
Operation
When the brake pedal is pressed down
q Brake pedal (1) pressing effort is transmitted to When brake of one side is operated
spool (5) through rod (2), spool (3) and spring (when the other brake failed)
(4). q Even when only one side of the brakes
q As spool (5) is pushed in the right direction, remains operable due to, for instance, oil leak
port (Ta) is closed and the oil from the pump on the front or rear brake system, brake pedal
activates the rear brake after being conducted (1) pressing effort moves in the right direction
through the accumulator, port (PA), port (A) after being transmitted mechanically through
and rear brake piston. spool (5) and spool (6).
q As spool (5) is pushed in the right direction, q Oil from the pump is conducted normally to the
spool (6) is also pushed in the right direction, brake piston of the healthy system to enable
closing port (Tb). The oil from the pump flows stopping the machine as needed in order to
through the accumulator, port (PB) and port (B) ensure safety.
to the front brake piston to activate the front
brake.
WA200-6 9
Balancing operation
q As the rear brake piston is filled with oil and the

oil pressure rises between port (PA) and port
(A), the oil being conducted to chamber (E)
through orifice (c) of spool (5) pushes spool (5)
in the left direction resisting repulsive force of
spring (4). As the result, port (PA) and port (A)
are disconnected.
q Since port (Ta) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q At the same time as spool (5) is moved to the
left, the front brake piston is filled up with oil,
increasing the oil pressure between port (PB)
and port (B). Thus, the oil conducted to cham-
ber (F) through orifice (d) of spool (6) pushes
back spool (6) in the left direction by the move
distance of spool (5). As the result, port (PB)
and port (B) are disconnected.
q Since port (Tb) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q The oil pressure of the rear brake circuit [port
(A) side] is balanced with the brake pedal
pressing effort, and the oil pressure of the front
brake circuit [port (B) side] is balanced with the
oil pressure of the rear brake circuit [port (A)
side].
q As spools (5) and (6) are moved in the right
direction to the stroke end, port (PA) and port
(A) as well as port (PB) and port (B) are fully
connected. As a result, oil pressure of the rear
brake cir cuit and the front br ake circuit
becomes equal to that from the pump.
q Braking force is adjustable by adjusting the
brake pedal pressing effort until spools (5) and
(6) are driven in the right direction to the stroke
end.
10 WA200-6
When brake pedal is released
q Releasing brake pedal (1) releases the pedal

pressing effort being applied to spool (5).
q Spool (5) is pushed back in the left direction by
the back pressure of the rear brake piston and
repulsive force of spring (7), and port (PA) and
port (A) are closed.
q At the same time, oil in the rear brake piston is
drained to the hydraulic tank through port (A)
and port (Ta), releasing the rear brake.
q At the same time as spool (5) is moved in the
left direction, spool (6) is also pushed back in
the left direction by the back pressure of the
front brake piston and repulsive force of spring
(7). As the result, port (PB) and port (B) are
closed.
q Oil in the front brake piston is drained to the
hydraulic tank through port (B) and port (Tb),
releasing the front brake.
WA200-6 11
Inching valve 1
P1: From HST pump port Y Outline

T2: To steering pump (suction side) q The inching valve, which is contained in brake
valve (2), reduces the control oil pressure of
1. Brake pedal the HST circuit responding to stroke (S) of
2. Brake valve spool (3) in order to reduce the capacity of the
3. Spool HST pump.
4. Body
12 WA200-6
Accumulator (for brake) 1
1. Cylinder
2. Free piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (1) and free piston (2) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charge pressure 3.5 ± 0.1 {35.7 ± 1}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
10 {102}
(MPa {kg/cm2})
WA200-6 13
Slack adjuster 1
A: From brake valve

B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm
Clearance between piston and size Shaft Hole clearance limit
4 body –0.065 +0.052 0.065 –
30 0.163
–0.098 0 0.150
Clearance between check valve –0.013 +0.015 0.013 –
5 and body
10
–0.028 0 0.043
0.048
Standard size Repair limit Replace

Installed Installed Installed
Free length Free length
6 Piston return spring length load load
11.8 N 9.8 N
87.5 48.2 —
{1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25
{5.5 kg}
—
{4.7 kg}
14 WA200-6
Function
q The slack adjuster is installed between the
brake valve and brake piston. It maintains the
time lag up to activation of the brake constant.
Operation
When brake is applied When brake is released
q The oil from the brake valve flows to port (A) q The oil being stopped between piston (1) and
and moves piston (1) in the right direction to brake piston pushes back piston (1) in the left
activate the brake using the oil being amassed direction, allowing the oil, equivalent in the vol-
between piston (1) and the brake piston. ume to piston (1) move distance, to return to
q The slack adjuster maintains the time lag up to the brake valve through port (A) then is drained
activation of the brake constant by operating to the hydraulic tank.
t he b r a k e u s i n g th e o i l b e i ng a m a s s e d
between piston (1) and the brake piston.
q If the oil between piston (1) and brake piston
goes low due to wear on the brake disc and
like, it pushes open check valve (2) to make up
the deficit.
WA200-6 15
Brake 1
Front brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
16 WA200-6
Unit: mm

6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (min.) — 0.4
Thickness of lining 1.0 0.8 (min.) — Replace

Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring 19.0 ±0.1 18.7
13 Load of spring
(when 2 pieces are piled)
Installed height Installed load Installed load
6.5 2,253 N 1,800 N

{230 kg} {184 kg}
Outline
q The front brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
WA200-6 17
Rear brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
18 WA200-6
Unit: mm
6 ±0.1 5.5
11 Depth of lining groove 0.8 (min.) — 0.4
Thickness of lining 1.0 0.8 (min.) —

Replace
Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring
19.0 ±0.1 18.7
13 Load of spring
(when 2 pieces are piled)
Installed height Installed load Installed load
2,253 N 1,800 N
6.5
{230 kg} {184 kg}
Outline
q The rear brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
WA200-6 19
Operation
When brake is operated
q As the brake pedal is pressed, oil pressure (P)

being supplied through the hydraulic tank,
pump and brake charge valve to the brake cyl-
inder acts on piston (2) in the brake cylinder to
move the piston.
Accordingly, disc (4) between piston (2), inner
ring (3), and outer ring (5) is stopped and the
brake is applied to the machine.
When brake is released
q If the oil pressure is released, piston (2) is

returned to the original position by the return-
ing force of spring (8) and clearance is made
between inner ring (3) and outer ring (5), and
disc (4) becomes free.
The linings stuck to disc (4) have cross
grooves on them. While disc (4) is rotating, oil
flows in those grooves to cool the linings.
20 WA200-6
Parking brake control 1
1. Parking brake lever 4. Control cable

2. Parking brake lever bottom switch 5. Transfer
3. Parking brake lever intermediate switch 6. Multi-disc brake lever
Outline
q The parking brake is built in transfer (5). On
this mechanical parking brake, operating the
multi-disc brake lever (6) from parking brake
lever (1) allows "applying" or "releasing" the
parking brake.
q Pulling parking brake lever (1) on the opera-
tor's seat pulls up the multi-disc brake lever
(6), which is connected with control cable (4),
"applying" the parking brake.
q Returning parking brake lever (1) to its original
position pushes down the multi-disc brake
lever (6), which is connected with control cable
(4), "releasing" the parking brake.
q As long as the parking brake is "applied", cur-
rent to the directional solenoid valve on the
HST pump is cut off and the swash plate of the
HST pump is maintained at the neutral posi-
tion.
WA200-6 21
Parking brake 1
1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft
Unit: mm
Thickness of plate
2.6 ±0.06 2.5
9
Strain on plate — 0.05 0.1
Replace
10
Strain on brake disc — 0.02 0.25
11 Load of wave spring

(height: 2.2 mm)
1,010 N
{103 kg}
±101 N
{±10.3 kg}
858 N
{87.6 kg}
Outline
q This parking brake is a wet multiple disc type
brake being operated mechanically to apply
braking to output shaft (8).
q Lever (1) is connected to the control cable. Ball
(3) provided between piston (4) and housing
(2), that are connected to lever (1), moves on
the slope of the piston groove responding to
the pulling distance of the parking brake lever.
By this move of the ball, piston (4) compresses
plate (5) and disc (6) to each other, thereby
applying brake to output shaft (8).
22 WA200-6
WA200-6 23
SEN03253-00

©2007 KOMATSU
All Rights Reserved
24
SEN03254-00
WA200-6
WA200-6 70001 and up

Undercarriage and frame

Axle mount and center hinge pin .................................................................................................................... 2
WA200-6 1
Axle mount and center hinge pin 1
2 WA200-6
1. Front axle Outline

2. Tension bolt q Front axle (1) receives the force during work
3. Rear axle directly. Thus, it is fixed directly to front fame
4. Frame lock bar (5) with tension bolt (2).
5. Front frame q Rear axle (3) is designed to sway at the center
6. Center hinge pin of rear frame (7) so that each tire may contact
7. Rear frame the ground surface even when the machine is
8. Additional counterweight (if equipped) traveling on soft ground.
9. Counterweight q Front frame (5) and rear frame (7) are coupled
by the center hinge pin (6) with the bearing
between them. The right and left steering cylin-
ders connect the front frame (5) and rear frame
(7). They adjust the bending angle or the turn-
ing radius of the frame according to move of
the cylinder.
WA200-6 3
4 WA200-6
Unit: mm
Clearance between upper hinge pin size Shaft Hole clearance limit
1 and rear frame (Small) –0.038 +0.100 0.038 –
50 —
–0.068 0 0.168
Clearance between upper hinge pin –0.038 +0.25 0.038 –
2 and spacer
50
–0.068 0 0.318
—
Clearance between upper hinge pin –0.038 0 0.026 –

3 and bearing
50
–0.068 –0.012 0.068
—
Clearance between upper hinge pin –0.073 0.023 –

4 and rear frame (Large)
66
–0.103
±0.05
0.153
—
Clearance between front frame and –0.08 –0.02 –0.04 –

5 spacer
105
–0.68 –0.12 0.66
—
Clearance between front frame and 0 –0.02 –0.120 –

6 upper hinge bearing
105
–0.015 –0.12 –0.005
—
Replace
Clearance of press fitting part of +0.07 –0.05 –0.220 –
7 upper hinge pin seal
89
–0.02 –0.15 –0.030
—
Clearance between lower hinge pin –0.20 +0.083 0.077 –

8 and rear frame bushing
70
–0.21 +0.123 0.127
—
Clearance between lower hinge pin –0.20 –0.097 0.078 –

9 and bearing
70
–0.21 –0.122 0.113
—
10 Clearance between front frame and

lower hinge bearing
89
–0.1
–0.12
–0.05
–0.15
–0.05 –
0.07
—
11 Clearance
bushing
between rear frame and
80
+0.084
+0.059
+0.054
0
–0.084 –
–0.005
—

12 Height of upper hinge spacer
23 ±0.1 —
13 Standard thickness of shim

between upper hinge and retainer
1.3
14 Standard thickness of shim

between upper hinge and retainer
0.8
Adjust
3.92 – 5.88 Nm {0.4 – 0.6 kgm} (when shim is adjusted)
15 Tightening torque of upper hinge
retainer mounting bolt
59 – 74 Nm {6.0 – 7.5 kgm} (final value)
WA200-6 5
Unit: mm
1 Thickness of thrust plate 0
10 —
–0.15
+0.3
2 Thickness of thrust washer 5
–0.1
—
Standard Tolerance Standard Clearance Replace

Clearance between shaft and hole size Shaft Hole clearance limit
3 on front support side –0.043 +0.550 0.093 –
170 —
–0.106 +0.050 0.656
Clearance between shaft and hole –0.043 +0.550 0.093 –
4 on rear support side
170
–0.106 +0.050 0.656
—
Standard thickness of shim in thrust

5 cap
0.2 —
6 WA200-6
WA200-6 7
SEN03254-00

©2007 KOMATSU
All Rights Reserved
8
SEN03255-00
WA200-6
WA200-6 70001 and up

Hydraulic system
Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control lever linkage ............................................................................................................. 4
Hydraulic tank ................................................................................................................................................. 6
4-gear pump.................................................................................................................................................... 8
Work equipment control valve........................................................................................................................11
PPC valve ..................................................................................................................................................... 27
Lock valve ..................................................................................................................................................... 36
Accumulator (for PPC circuit)........................................................................................................................ 37
ECSS valve................................................................................................................................................... 38
Accumulator (for ECSS)................................................................................................................................ 40
WA200-6 1
Work equipment hydraulic piping diagram 1
2 WA200-6
1. Work equipment control valve Outline

2. Bucket cylinder q The hydraulic system is consisted of the HST,
3. Hydraulic tank steering, work equipment, brake, cooling fan
4. Work equipment PPC valve and transfer lubrication circuit. The work equip-
5. Lock valve ment circuit controls move of the lift arm and
6. Oil cooler bucket.
7. Check valve q The oil in hydraulic tank (3) is supplied to work
8. 4-gear pump equipment control valve (1) by work equipment
• Steering pump pump of 4-gear pump (8). When each spool of
• Work equipment pump the lift arm and bucket of work equipment con-
• Brake and cooling fan pump trol valve (1) is at the Hold position, the oil
• Transfer lubrication pump flows the drain circuit of work equipment con-
9. Accumulator (for ECSS) (if equipped) trol valve (1), is filtered on the return filter on
10. Lift cylinder hydraulic tank (3), then is returned to hydraulic
11. ECSS valve (if equipped) tank (3).
12. Accumulator (for PPC circuit) q Operating the work equipment control lever
operates the lift arm spool or bucket spool of
work equipment PPC valve (4).
The oil from work equipment PPC valve (4)
operates respective spools of work equipment
valve (1) with its oil pressure, then sends the
oil pressure to lift cylinder (10) or bucket cylin-
der (2) to operate the lift arm or bucket.
q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (1). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q Accumulator (for PPC circuit) (12) is installed
on the PPC pilot circuit so that the work equip-
ment can be lowered to the ground even while
the engine is stopped.
q Hydraulic tank (3) is pressurized, enclosed,
and equipped with the breather having the
relief valve, which doubles the oil filler cap
function. The breather applies pressure to the
tank and, at the same time, prevents genera-
tion of negative pressure in the tank to prevent
cavitation in the pump.
WA200-6 3
Work equipment control lever linkage 1
Mono-lever type
1. Work equipment control lever

2. Wrist rest
3. Lock valve
4. Work equipment lock lever
5. Work equipment PPC valve
6. Wrist rest height adjustment lever
4 WA200-6
WA200-6 5
Hydraulic tank 1
1. Oil filler cap and breather Specifications

2. Return filter Capacity of hydraulic tank (l) 83
3. Hydraulic tank
Quantity of oil in hydraulic tank (l) 58
4. Drain plug
5. Sight gauge Set pressure of bypass valve 0.2
6. Return filter bypass valve (MPa {kg/cm2}) {2.04}
7. Check valve Cracking pressure of check valve 0.1 ± 0.02
(MPa {kg/cm2}) {0.98 ± 0.2}
6 WA200-6
Breather 1
1. Oil filler cap

2. Case
3. Lock-resetting knob
4. Sleeve
5. Poppet
6. Filter element
Prevention of negative pressure in tank

q Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated.
At this time, sleeve (4) is opened by the differ-
ential pressure between the tank pressure and
the atmospheric pressure to prevent genera-
tion of the negative pressure.
(set pressure of air intake valve:
3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2})
Prevention of pressure rise in tank

q While the hydraulic circuit is in operation, the
oil level in the tank rises as the hydraulic cylin-
ders operate, and the temperature rises. Con-
sequently, the pressure in the tank rises, too.
If the pressure in the tank rises beyond the set
level, poppet (5) is activated to release the
pressure in the tank to prevent rise of pressure
in the tank.
(set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
WA200-6 7
4-gear pump 1
(steering, work equipment, brake, cooling fan and transfer lubrication)
SAR (2)50 + 32 + SB (1)12 + 12
1. Steering pump Outline

2. Work equipment pump q The 4-gear pump is installed on the HST
3. Brake and cooling fan pump pump. The axial rotation drives this gear to
4. Transfer lubrication pump supply pressurized oil to the steering, work
equipment, brake, cooling fan and transfer.
8 WA200-6
Unit: mm
Type Standard clearance Clearance limit
SAR(2)50
5 Side clearance SAR(2)32
0.10 – 0.15 0.19
SBR(1)12
SBR(1)12
SAR(2)50 0.06 – 0.125
Clearance between inside diameter SAR(2)32 0.06 – 0.125
6 of plain bearing and outside 0.20
Replace
diameter of gear shaft SBR(1)12
0.068 – 0.115
SBR(1)12
Type Standard size Allowance Repair limit
SAR(2)50 12
0
SAR(2)32 12
7 Pin driven depth –0.5
SBR(1)12 10 —
+0.5
SBR(1)12 7
0
8 Torque of spline rotating shaft 9.8 – 23.5 Nm {1.0 – 2.4 kgm}
Discharge Standard Allowable

Speed
Type pressure delivery delivery
(rpm)
(MPa {kg/cm2}) (l/min) (l/min)
Delivery —
— Oil: SAE10WCD SAR(2)50 138 127
Oil temperature: 45 – 55°C SAR(2)32 20.6 {210} 88 81
3,000
SBR(1)12 32 30
SBR(1)12 2.9 {30} 32 30
WA200-6 9
10 WA200-6
Work equipment control valve 1
2-spool type
A1: To bucket cylinder head PA1: From work equipment PPC valve
A2: To lift arm cylinder head PA2: From work equipment PPC valve
B1: To bucket cylinder bottom PB1: From work equipment PPC valve
B2: To lift arm cylinder bottom PB2: From work equipment PPC valve
P: From pump T: To hydraulic tank
WA200-6 11
12 WA200-6
1. Main relief valve

2. Bucket spool
3. Lift arm spool
5. Check valve
6. Suction valve
Unit: mm
Free length x
Installed
7 Spool return spring
diameter
length
92.2 N 73.7 N
42.53 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
55.9 N 44.7 N
8 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}
—
{4.56 kg}
deformed, replace
spring
111 N 88.7 N
9 Spool return spring 53.35 x 12 38.5
{11.3 kg}
—
{9.04 kg}
72.6 N 58.1 N
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
11 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
WA200-6 13
14 WA200-6
3-spool type
A1: To service actuator PA1: To service PPC valve

A2: To bucket cylinder head PA2: To work equipment PPC valve
A3: To lift arm cylinder head PA3: To work equipment PPC valve
B1: To service actuator PB1: To service PPC valve
B2: To bucket cylinder bottom PB2: To work equipment PPC valve
B3: To lift arm cylinder bottom PB3: To work equipment PPC valve
P: From pump T: To hydraulic tank
WA200-6 15
16 WA200-6
1. Main relief valve

2. Service spool
3. Bucket spool
4. Lift arm spool
6. Check valve
7. Suction valve
Unit: mm
Free length x
Installed
8 Spool return spring
diameter
length
92.2 N 73.7 N
42.53 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
55.9 N 44.7 N
9 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}
—
{4.56 kg}
deformed, replace
spring
111 N 88.7 N
10 Spool return spring 53.35 x 12 38.5
{11.3 kg}
—
{9.04 kg}
72.6 N 58.1 N
{7.4 kg}
—
{5.92 kg}
29.4 N 23.5 N
12 Check valve spring 39.5 x 11.2 25
{3 kg}
—
{2.4 kg}
WA200-6 17
Relief valve
q As the pressurized oil in ports (A) and (B)
reaches the set pressure of spring (4), pilot
poppet (3) opens, leading the pressurized oil in
port (B) to port (C) through port (D), and pres-
sure in port (B) is decreased.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q As the pressure in port (B) goes low, the orifice
Function of main valve (1) generates differential pres-
q This valve is installed in the inlet of the work sure between ports (A) and (B). As a result, the
equipment control valve. When the oil pressure main valve is pushed open, and pressurized oil
increases beyond the specified level, it drains in port (A) flows to the drain circuit through port
the oil to the hydraulic tank. Above process (C) to release the abnormal pressure.
protects the work equipment circuit by restrict- q Using the repulsive force of spring (4) can
ing the maximum pressure. increase or decrease the set pressure.
q When increasing the set pressure, remove the
Operation cap nut to loosen the locknut and screw the
q Port (A) and port (C) are connected to the adjustment screw (5). When decreasing,
pump circuit and the drain circuit, respectively. loosen the adjustment screw (5).
Pressurized oil fills up port (B) after flowing
through the orifice of main valve (1). Pilot pop-
pet (3) is contacted with valve seat (2).
18 WA200-6
Suction safety valve
1. Piston
2. Main valve q If abnormal pressure is generated in port (A)
3. Piston spring and reaches the set pressure of spring (6),
4. Valve seat poppet (5) opens to drain the pressurized oil in
5. Poppet port (C) through port (D) and outer circumfer-
6. Poppet spring ence (a) of suction valve (7).
7. Suction valve
8. Suction valve spring
9. Adjustment screw
Function
q This valve is installed in the bucket cylinder cir-
cuit of the work equipment control valve. When
the bucket lever is set to the neutral position, if
abnor mal pr ess ure is gener ated due to
impacts to the cylinder, the abnormal pressure
is relieved through this valve to protect the
hydraulic equipment such as cylinder from
damage.
q And if negative pressure is generated in the
cylinder circuit, this valve works as a suction
valve. q Opening of poppet (5) decreases the pressure
in port (C), and piston (1) moves to the right.
Operation Piston (1) contacts the tip of poppet (5) and the
pressurized oil is drained from port (D) through
orifice (b).
1. Operation as safety valve
q Port (A) and port (B) are connected to the cyl-
inder circuit and drain circuit, respectively.
q Pressurized oil in port (A) is conducted to port
(C) through piston (1) hole. Main valve (2) is
contacted against the left side due to the rela-
tion (d2) < (d3).
q The relation between the size of cross sec-
tional diameters (cross section areas) can be
presented as (d5) > (d4) > (d1) > (d3) > (d2).
WA200-6 19
q Since the pressure in port (C) is lower than that Suction valve
in port (A), main valve (2) moves to the right
and the pressurized oil is conducted from port
(A) to port (B) to prevent generation of abnor-
mal pressure.
q Even if abnormal pressure is generated, suc-
tion valve (7) with the large cross sectional
diameter remains not operated because of the
relation (d1) < (d4).
1. Main poppet
2. Sleeve
3. Spring
Function
q This valve prevents to generate negative pres-
sure on the circuit.
Operation
2. Operation as suction valve q If negative pressure is generated in port (A) (lift
q If negative pressure is generated on the cylin- arm cylinder head) ([if a pressure lower than
der circuit, negative pressure is set on both that in the tank circuit port (B) is generated],
port (A) and port (C) because they are con- main poppet (1) is opened by the difference in
nected to each other. Suction valve ( 7) area between (d1) and (d2), and the pressur-
receives the pressurized oil by the difference in ized oil flows cylinder port (A) from tank port
area between (d4) and (d1). (B).
q When the differential pressure between port
(B) and port (A) increases beyond the set pres-
sure, suction valve (7) moves to the right. Thus
the pressurized oil flows from port (B) to port
(A) to prevent generation of negative pressure
in port (A).
20 WA200-6
Operation of work equipment control valve

1. When lift arm and bucket spool are at the neutral position
Operation
q The pressurized oil flows to port (A) through q The bypass circuit is open since lift arm spool
pump (1) and the priority valve. And the maxi- (4) is at the neutral position. Thus, the pressur-
mum pressure is regulated by relief valve (2). ized oil in port (B) enters port (C) of the drain
q The bypass circuit is open since bucket spool circuit passing through in vicinity of the spool,
(3) is at the neutral position. Thus, the pressur- and returns to the hydraulic tank through the
ized oil in port (A) flows to port (B) passing filter.
through in vicinity of the spool.
WA200-6 21
2. When lift arm spool is at raise position
Operation
q Pulling the work equipment control lever pulls
out lift arm spool (4) to set it to the raise posi-
tion.
q The pressurized oil from pump (1) flows to the
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder bottom through port (D).
q The pressurized oil on the cylinder head side
returns to the hydraulic tank through port (E)
and drain port (C). Thus, the lift arm is moved
upward.
22 WA200-6
3. When lift arm spool is at lower position
Operation
q Pushing the work equipment control lever
pushes in lift arm spool (4) to set it to the lower
position.
q The pressurized oil from pump (1) flows to the
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder rod side through port (E).
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (D)
and drain port (C). Thus, the lift arm is moved
downward.
WA200-6 23
4. When lift arm spool is at float position
Operation
q Pushing the work equipment control lever fur- q As long as the bucket is contacting against the
ther from the lower position pushes in lift arm ground surface, the lift arm can be raised or
spool (4) to set it to the float position. lowered due to undulations on the ground sur-
q The pressurized oil from pump (1) flows to the face.
q Since the pressurized oil in the bypass circuit
flows to the drain circuit by the spool, check
valve (5) cannot be pushed open.
q In addition, the lift arm descends by its own
weight since both the raise circuit (D) and
lower circuit (E) of the lift arm cylinder are con-
nected to the drain circuit.
24 WA200-6
5. When bucket spool is at tilt position
Operation
q Pulling the work equipment control lever pulls
out bucket spool (3) to set it to the tilt position.
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (G) flows to the
cylinder bottom side.
q The pressurized oil on the cylinder rod side
returns to the hydraulic tank through port (H)
and drain port (C). Thus, the bucket tilts.
WA200-6 25
6. When bucket spool is at dump position
Operation
q Pushing the work equipment control lever
pushes in bucket spool (3) to set it to the dump
position.
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (H) flows to the
cylinder rod side.
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (G)
and drain port (C). Thus, the bucket dumps.
26 WA200-6
PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
Work equipment PPC valve

Mono lever type
P: From HST charge pump P3: To lift arm valve (raise)

P1: To bucket valve (tilt) P4: To lift arm valve (lower, float)
P2: To bucket valve (dump) T: To hydraulic tank
WA200-6 27
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Piston
4. Rod 10. Retainer
5. Disc 11. Body
6. Nut (for connecting lever) 12. Filter
28 WA200-6
Operation
1. When in neutral
1) Bucket PPC valve 2) Lift arm PPC valve

q Ports (PA) and (PB) of the control valve q Ports (PA) and (PB) of the control valve (lift
(bucket valve) and ports (P1) and (P2) of the arm valve) and ports (P3) and (P4) of the PPC
PPC valve are connected through fine control valve are connected through fine control hole
hole (f) of spool (1) to drain chamber (D). (f) of spool (1) to drain chamber (D).
WA200-6 29
2. When in fine control mode

(neutral o fine control)
q If rod (4) and piston (9) are pushed by disc (5),
retainer (10) is pushed and spool (1) is also
pushed downward through metering spring (2).
q When fine control hole (f) is shut off from drain
chamber (D), almost simultaneously, it is con-
nected to pump pressure chamber (PP).
q The pilot pressurized oil from the HST charge
pump flows through fine control hole (f) and
port (P1) to port (PB).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (11) (where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)) does not change until
retainer (10) comes in contact with spool (1).
q Metering spring (2) is compressed in propor-
tion to the stroke of the control lever.
q Pressure in port (P1) also increases in propor-
tion to the stroke of the control lever.
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.
30 WA200-6
3. When in fine control mode 4. When lever is operated to stroke end

(when control lever is returned) q Disc (5) and rod (4) push down piston (9) and
q As disc (5) begins to return, the force of center- retainer (10) pushes down spool (1).
ing spring (3) and the pressure in port (P1) q Fine control hole (f) is disconnected from drain
push up spool (1). chamber (D) and connected to the pump pres-
q Because of this, fine control hole (f) is con- sure chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot pressure oil from the HST charge
ized oil at port (P1) is released. pump flows through fine control hole (f) and
q If the pressure in port (P1) went abnormally port (P1) into chamber (PB) to push the control
low, spool (1) is pushed down by metering valve spool.
spring (2). q The oil returning from chamber (PA) flows
q Fine control hole (f) is disconnected from drain through port (P2) and fine control hole (f') into
chamber (D) and almost simultaneously con- drain chamber (D).
nected to the pump pressure chamber (PP).
q The pump pressure is supplied until the pres-
sure in port (P1) recovers to a pressure equiv-
alent to the position of the lever.
q When the control valve spool returns, the pres-
surized oil in drain chamber (D) flows in
through fine control hole (f') of the valve which
is not in operation and flows through port (P2)
into chamber (PA).
WA200-6 31
5. When lift arm is "float"

q If disc (5) pushes down rod (4) and piston (9)
on port (P4) "lower" side, the detent starts
operation before the stroke end. (the operating
effort of the lever becomes heavy.)
q If rod (4) is pushed down further, the detent
operates to keep the lift arm in "float" state
even if the lever is released.
q At the same time, the control valve is also
moved to the "float" position to keep the lift arm
in float condition.
6. When "float" state of lift arm is reset

q When returning disc (5) from the "float" posi-
tion, the rod is pushed down with a force larger
than absorptive power of the solenoid.
q The "float" state also can be reset and the
lever can be returned to the "neutral" position
by turning off the current in the solenoid (de-
energizing the solenoid).
q The lift arm raise and bucket tilt operations are

carried out similarly to the above.
32 WA200-6
WA200-6 33
Attachment PPC valve (if equipped)
a For the details of operation, see the paragraph of "Work equipment PPC valve".
34 WA200-6
P: From self pressure reducing valve

P1: To attachment valve
P2: To attachment valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
Free length x
Installed
8 Centering spring
diameter
length If damaged or
deformed, replace
41.1 x 15.5 29 36.3 N — 29.0 N spring
{3.7 kg} {2.96 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22 {1.7 kg} — {1.36 kg}
WA200-6 35
Lock valve 1
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The lock valve is installed between the HST
charge pump and work equipment PPC valve.
As the work equipment lock lever is set to the
"Lock" position, this valve, in conjunction with
the work equipment lock lever, cuts off the oil
of the PPC circuit to disable the work equip-
ment operation.
36 WA200-6
Accumulator (for PPC circuit) 1
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q The accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.
Specifications
Amount of gas (cc) 500
Charged pressure 1.18(+0.2/0) {12(+2/0)}
Max. pressure used
3.92 {40}
(MPa {kg/cm2})
WA200-6 37
ECSS valve 1
(if equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
P: From work equipment pump

A: From lift cylinder bottom
B: From lift cylinder head
SP: To accumulator (for ECSS)
38 WA200-6
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
WA200-6 39
Accumulator (for ECSS) 1
(if equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q The accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.
Specifications
Amount of gas (cc) 2,000
Charged pressure 1.67 ± 0.05 {17 ± 0.5}
Max. pressure used
20.6 {210}
(MPa {kg/cm2})
40 WA200-6
WA200-6 41
SEN03255-00

©2007 KOMATSU
All Rights Reserved
42
SEN03256-00
WA200-6
WA200-6 70001 and up

Work equipment
Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 4
Bucket positioner and boom kick-out .............................................................................................................. 6
Work equipment cylinder .............................................................................................................................. 12
WA200-6 1
Work equipment linkage 1
2 WA200-6
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
Clearance between bushing and pin size Shaft Hole clearance limit
7 at each end of bucket link –0.030 +0.174 0.130 –
65 1.0
–0.076 +0.100 0.250
Clearance between bushing and pin –0.030 +0.174 0.130 –
8 connecting lift arm and bucket
65
–0.076 +0.100 0.250
1.0
Clearance between bushing and pin –0.030 +0.174 0.130 –

9 connecting lift arm and frame
75
–0.076 +0.100 0.250
1.0
Clearance between bushing and pin

–0.030 +0.174 0.130 – Replace
10 connecting bucket cylinder bottom 70
–0.076 +0.100 0.250
1.0
and frame (Replace pin when
it has scuff marks,
Clearance between bushing and pin too.)
–0.030 +0.174 0.130 –
11 connecting bucket cylinder rod and 70
–0.076 +0.100 0.250
1.0
bell crank
12 Clearance between bushing and pin

connecting bell crank and lift arm
75
–0.030
–0.076
+0.174
+0.100
0.130 –
0.250
1.0

–0.030 +0.174 0.130 –
13 connecting lift cylinder rod and lift 65
–0.076 +0.100 0.250
1.0
arm
–0.030 +0.174 0.130 –
14 connecting lift cylinder bottom and 65
–0.076 +0.100 0.250
1.0
frame
Width of boss Width of hinge
Standard
Standard Standard clearance
15 Connecting
and frame
part of bucket cylinder
size
Tolerance
size
Tolerance
0
80 83 ±1.5 1.5 – 5.0
-0.5
Adjust shim so that
16 Connecting
frame
part of lift arm and
85 — 89 ±1.5 2.5 – 5.5 clearance will be
below 1.5 mm on
17 Connecting
bucket
part of lift arm and
85 — 88
+3.0
0
3.0 – 6.0 each side
18 Connecting
bucket
part of bucket link and
85 ±1.0 88
+3.0
0
2.0 – 7.0
19 Connecting
frame
part of lift cylinder and
85
0
–0.5
89 ±1.5 2.5 – 6.0
20 Connecting
bucket link
part of bell crank and
85 ±1.0 88 ±1.5 0.5 – 5.5
Replace
21 Connecting
arm
part of bell crank and lift
148 ±0.5 151 ±1.5 1.0 – 5.0
22 Connecting part of bucket cylinder

and bell crank
80
0
-0.5
88 ±1.5 6.5 – 10.0 Adjust shim so that
clearance will be
below 1.5 mm on
23 Connecting
cylinder
part of lift arm and lift
85 — 89 ±1.5 2.5 – 5.5 each side
WA200-6 3
Bucket 1
1. Bucket 3. Bucket teeth (if equipped)

2. Bolt-on cutting edge
Unit: mm
4 Wear of cutting edge (Thickness)
25.4 15
Reverse or replace
5 Wear of cutting edge (Length) 62 5
6 Wear of bucket teeth 35 18 Replace
Clearance in adapter mounting

7 parts
Max. 0.5 — Adjust or replace
4 WA200-6
WA200-6 5
Bucket positioner and boom kick-out 1
1. Bucket positioner proximity switch 4. Bucket cylinder

2. Boom kick-out proximity switch (if equipped) 5. Lift arm
3. Bar 6. Plate (if equipped)
Unit: mm
Clearance on bucket positioner
7 proximity switch
3–5
Adjust
Clearance on boom kick-out
8 proximity switch
3–5
6 WA200-6
Outline
Bucket positioner
q The bucket positioner is driven electrically.
When the bucket is returned to an angle from
the dump position to the tilt position, the bucket
positioner returns the work equipment (bucket)
control lever from the "tilt" position to the "hold"
position to automatically stop the bucket at a
proper digging angle.
q Bar (3) is fixed to the rod side of bucket cylin-
der (4). And proximity switch (1) is fixed to the
cylinder side.
q Moving the work equipment (bucket) control
lever from "dump" position to "tilt" position
moves the rod of bucket cylinder (4) toward the
machine front side.
As bar (3) moves a specific distance, proximity
switch (1) detects that it is away from the sens-
ing face, and returns the work equipment
(bucket) control lever to "hold" position.
Boom kick-out
(if equipped)
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (6) is fixed to lift arm (5). And proximity
switch (2) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (5) upward.
As plate (6) moves a specific distance, proxim-
ity switch (2) detects that it is away form the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
WA200-6 7
Operation of proximity switch
When bucket is tilted
q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the tilt position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.
8 WA200-6
a The power supply for detent solenoid (6) oper-

ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alter-
nator relay (11) as long as the engine is
stopped.
As the result, the work equipment (bucket)
control lever (7) cannot be moved and held in
the tilt position as long as bar (2) is positioned
in sensing face of proximity switch (1).
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned ON
Bucket positioner relay ON
Work equipment PPC valve detent

Power ON
solenoid circuit
Energized
solenoid
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned OFF
Bucket positioner relay OFF
Work equipment PPC valve

Power OFF
detent solenoid circuit
De-energized
solenoid
q As the bucket is tilted and moved away from

the position set by the positioner, in other
words, as bar (2) moves away from the sens-
ing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket posi-
tioner relay (4) is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held bucket spool (8) receives the reaction
force of spring (9) and returns work equipment
(bucket) control lever (7) to "hold" position.
WA200-6 9
When lift arm is raised
q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the raise position moves spool (8) to
moves on to the sensing face of proximity the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.
10 WA200-6
a The power supply for detent solenoid (6) oper-

ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is cut off since L sig-
nal from alternator (10) is not sent to alternator
relay (11) as long as the engine is stopped.
As the result, the work equipment (lift arm)
control lever (7) cannot be moved and held in
the raise position as long as plate (2) is posi-
tioned in sensing face of proximity switch (1).
Function of proximity switch
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned ON
Boom kick-out relay ON

Power ON
solenoid circuit
Energized
solenoid
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned OFF
Boom kick-out relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As lift arm (3) is raised and moved away from

the position set by the boom kick-out, namely
as plate (2) moves away from the sensing face
of proximity switch (1), the lamp of proximity
switch (1) lamp goes off and boom kick-out
relay (4) is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held lift arm spool (8) receives the reaction
force of spring (9) and returns work equipment
(lift arm) control lever (7) to the "hold" position.
WA200-6 11
Work equipment cylinder 1
Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between –0.030 +0.262 0.097 –
1 piston rod and bushing Lift 65 0.666 Replace bushing
–0.104 +0.067 0.366
Bucket 65 –0.030 +0.262 0.097 – 0.666

–0.104 +0.067 0.366
12 WA200-6
WA200-6 13
SEN03256-00

©2007 KOMATSU
All Rights Reserved
14
SEN03257-00
WA200-6
WA200-6 70001 and up

Cab and its attachments

Cab ................................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4
WA200-6 1
2 WA200-6
Cab 1
1. Front working lamp

2. Radio antenna
3. Door (left)
4. Air conditioner external air filter
5. Front glass
6. Front wiper
7. KOMTRAX GPS antenna (if equipped)
8. KOMTRAX communication antenna (if equipped)
9. Door (right)
10. Rear wiper
WA200-6 3
Air conditioner 1
Air conditioner piping diagram 1
4 WA200-6
1. Hot water take-out piping Specifications

2. Compressor Refrigerant used R134a
3. Condenser
4. Receiver Refrigerant refilling level (g) 1,150
5. Hot water return piping
6. Refrigerant piping
7. External air filter
8. Internal/external air changeover damper
9. Blower unit
10. Air conditioner unit
11. Dual pressure switch
12. Air outlet duct
13. Cool and hot box (if equipped)
14. Internal air filter
WA200-6 5
Refrigerant circuit diagram
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
Table of tightening torque for refrigerant piping adapter

Unit: Nm {kgm}
12 – 15 {1.2 – 1.5}
7 Air conditioner unit refrigerant inlet side
(screw size: M16 x 1.5)
30 – 35 {3.1 – 3.6}
8 Air conditioner unit refrigerant outlet side
8 – 12 {0.8 – 1.2}
9 Receiver refrigerant pipe set bolt
Retighten
20 – 25 {2.0 – 2.6}
10 Compressor refrigerant piping lock bolt (screw size: M8 x 1.25)
20 – 25 {2.0 – 2.6}
11 Condenser refrigerant inlet side (screw size: M22 x 1.5)
12 – 15 {1.2 – 1.5}
12 Condenser refrigerant outlet side (screw size: M16 x 1.5)
6 WA200-6
Air conditioner unit 1
A: From receiver Outline

B: To compressor q The vertical air conditioner unit on which evap-
C: Hot water inlet orator (1) and heater core (2) is synchronized
D: Hot water outlet with the blower and intake unit to generate cool
and hot air.
1. Evaporator q The temperature adjusting switch on the air
2. Heater core conditioner panel controls air mix dampers (3)
3. Air mix damper (upper) and (4) to adjust the spurting out temperature.
4. Air mix damper (lower)
5. Expansion valve Cooler
6. Blower controller
q The cooler circulates refrigerant through evap-
7. Blower motor relay
orator (1) to cause heat exchange (dehumidifi-
8. Compressor clutch relay
cation and cooling).
9. Air mix damper actuator
q Air taken in by the blower and intake unit is
10. Evaporator temperature sensor
cooled with evaporator (1) and then blown out
from the duct and grill.
Heater
q The heater circulates engine coolant in heater
core (2) to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core (2) and then blown out
through the duct and grill.
WA200-6 7
Functions of major components

Evaporator Air mix damper actuator
q Evaporator fin is cooled by the low-pressure, q It starts the built-in motor receiving signal cur-
low-temperature refrigerant gas being sent rent from the air conditioner panel in order to
from the expansion valve. Air from the blower open or close the air mix damper through the
motor is cooled and dehumidified when pass- link mechanism.
ing through the fin. q The motor rotating direction is determined as
the air conditioner panel reads the position of
Heater core the potentiometer being built in the actuator.
q Fin of the heater core is heated by the hot This reading is done as the target temperature
water (cooling water) being sent from the is set from the temperature adjustment switch
engine. Air from the blower motor is heated as on the air conditioner panel.
it passes through the fin. q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
Expansion valve motor, moves away or signal current from the
q This valve converts high-pressure, high-tem- air conditioner panel is turned "OFF".
perature liquid refrigerant from the receiver to
low-pressure, low-temperature misty refriger- Evaporator temperature sensor
ant through the throttling function. q In order to prevent freezing of the evaporator, it
It controls flow rate of refrigerant by changing senses the evaporator temperature and sends
level of throttling depending on the thermal necessary signals to the air conditioner panel.
load in the operator's cab. The signal sent to the air conditioner panel is
used to control the compressor. As the result,
Blower controller temperature of the air blown out of the grill is
q It controls the blower motor speed receiving adjusted depending on the volume of refriger-
signal current from the air conditioner panel. ant circulated in the evaporator.
Blower motor relay Dual pressure switch

q Signal current from the air conditioner panel q If abnormally low or high pressure was gener-
controls the relay coil. As the relay coil is ener- ated in the refrigerant circulation circuit, this
gized and the switch is turned "ON", power is switch releases the magnet clutch of the com-
supplied to the blower motor. pressor to protect a series of cooler-related
equipment.
Compressor clutch relay
q Signal current from the air conditioner panel
dual pressure switch is used for controlling the
relay coil. As the relay coil is energized and the
switch is turned "ON", the magnet clutch of the
compressor is connected.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
8 WA200-6
Blower and intake unit 1
1. Blower motor assembly Functions of major components

2. Internal/external air changeover damper actuator Blower motor assembly
3. Internal/external air changeover damper q It suctions air by rotating the fin installed on the
blower motor. And it is also used for sending
the absorbed air to the evaporator and heater
core.
Internal/external air changeover damper actua-

tor
q Receiving signal current from the air condi-
tioner panel, it starts the built-in motor to open
or close the internal/external air changeover
damper through the link mechanism.
q The motor rotation direction is determined from
the internal/external air changeover switch on
the air conditioner panel.
q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
motor, moves away or signal current from the
air conditioner panel is turned "OFF".
WA200-6 9
Compressor 1
A: From air conditioner unit Function

B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature misty
refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders –
7 – 29.3 x 27.4
Bore x Stroke (mm)
Piston capacity (cc/rev) 129.2
Allowable maximum speed

4,000
(rpm)
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume

135
(cc)
10 WA200-6
Condenser 1
A: From compressor Function

B: To receiver q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
compressor.
a If the fin crushes or is clogged with dusts, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation area (m )
2
6.55
Max. pressure used
3.6 {36}
(MPa {kg/cm2})
WA200-6 11
Receiver 1
A: From condenser Function

B: To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the con-
1. Sight glass denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
12 WA200-6
WA200-6 13
Air conditioner panel 1
Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Spurting out All segments below applicable level come
1 See above drawing
temperature on (8-step display)
Gauge
Air blasting All segments below applicable level come
2 See above drawing
volume on (4-step display)
The display indicates which is currently
Circulation of When circulating Liquid
taking place - internal air circulation or Black
internal air and internal air and crystal
3 external air introduction - responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air
Turns "ON" air conditioner switch, this lamp
4 Air conditioner conditioner switch
lights up.
is "ON"
Switch block
No. Switch name Function Operation
Circulation of
This switch is used to select either the circulation of internal air or
internal air
Internal/external air introduction of external air
5 IO
changeover switch (pilot display on the display unit is switched depending on the switch
Introduction of
setting)
external air
6 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
It turns on or off main power supply of the air conditioner.
7 Main power switch ON: Settings done during "OFF" are indicated on the display unit. OFF io ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO io HI
(adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It controls the spurting out temperature
9 IO
switch (8-step adjustment)
High temperature
14 WA200-6
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals

JAE IL-AG5-14P [CN-C48] JAE IL-AG5-22P [CN-C47]
Input and Input and
Pin No. Signal name output Pin No. Signal name output
signals signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
Internal/external air changeover 3 Blower motor relay Input
3 Input
damper actuator limiter
Internal/external air changeover
4 External air temperature sensor Input 4 damper actuator output 1 Output
5 Evaporator temperature sensor Input 5 Internal/external air changeover Output

damper actuator output 2
6 Internal air temperature sensor Input
6 Mode selector actuator output 2 Output
7 Starting switch (ON) Input
7 Mode selector actuator output 1 Output
8 Night lamp signal Input
8 Air mix damper actuator output 2 Output
9 NC —
9 Air mix damper actuator output 1 Output
10 NC —
10 Actuator potentiometer power supply —
11 NC — (5 V)
12 NC — 11 NC —
13 Day light sensor 2 Input 12 NC —
14 Day light sensor 1 Output 13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
Air mix damper actuator
18 potentiometer Input
19 Mode selector actuator potentiometer Input

20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
WA200-6 15
SEN03257-00

©2007 KOMATSU
All Rights Reserved
16
SEN03258-00
WA200-6
WA200-6 70001 and up

Electrical system, Part 1

Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 6
WA200-6 1
Machine monitor system 1
Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors controls the machine setting and adjustment functions are provided
condition with the sensors installed to various using the character display and the machine
parts of the machine, and then sends the result monitor mode selector switch, which is the
as network information to the machine monitor, operation switch of the character display.
which displays the information to notify the 1) Switching of traction level
operator of the machine condition. 2) Switching of HST reverse travel gear shift-
ing pattern
q The machine monitor displays the information 3) Display the odometer
in the operator mode or service mode. 4) Resetting the filter or oil replacement time
5) Input the telephone number
q The operator mode is used to display the infor- 6) Selecting the language
mation to the operator normally. The major 7) Adjusting the illuminance of nighttime light
functions used in the service mode are as fol- 8) Travel speed/engine speed display select-
lows. ing function
9) Function for setting display/no-display of
1. Items always displayed travel speed or engine speed to the char-
q Meters (speedometer or engine tachome- acter display
ter)
q Gauges (engine coolant temperature
gauge, HST oil temperature gauge and
fuel gauge)
q Pilot indicators
q Service meter
The following items are displayed accord-

ing to the set state of the optional device
selecting function.
q Travel speed or engine speed indication
on the character display
2. Items displayed when abnormality is detected

q Caution lamps
q Action code (while an action code is dis-
played, if the machine monitor mode
selector switch (>) is pressed and
released, the failure code (6 digits) is dis-
played.)
3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(maintenance monitoring function)
2 WA200-6
q The service mode function is provided for the 10. Machine serial number input function
ease of troubleshooting for the controllers on Enters the machine serial number to identify
the network (including the machine monitor the machine.
itself). The major functions used in this mode
are as follows. 11. Model selection function
Enters the information of applicable model.
1. Electrical system failure history display func-
tion 12. Initialize function
The electrical system failures of each controller Sets the machine monitor to the state set when
saved in the machine monitor are displayed. the machine is delivered.
The information of those failures is also
deleted with this function.
2. Mechanical system failure history display func-

tion
The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.
3. Real-time monitoring function

The input and output signals recognized by
each controller on the network are displayed in
real time.
4. Engine reduced-cylinder function

This function is used for the purpose of speci-
fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
5. No injection cranking function

Before restarting engine after a long-term stor-
ing of the machine, this function is used to
lubricate the engine internally.
6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
7. Maintenance monitoring function

Changes the filter or oil replacement time and
makes ON/OFF selection of the function.
8. Operating information display function

Displays fuel consumption per operating hour.
9. Optional device selecting function

Verifies the installation of optional devices or
changes their setting.
WA200-6 3
System circuit diagram

a Items marked with "*1" in drawing may or may not installed.
4 WA200-6
WA200-6 5
Machine monitor 1
1. HST oil temperature gauge 21. Quick coupler operation pilot lamp (*2)
2. HST oil temperature caution lamp 22. Cooling fan reverse rotation pilot lamp
3. Engine coolant temperature gauge 23. Maintenance caution lamp
4. Engine coolant temperature caution lamp 24. Parking brake reminder caution lamp
5. Speedometer or engine tachometer 25. Battery charge circuit caution lamp
6. Turn signal pilot lamp (left) 26. Steering oil pressure caution lamp (*2)
7. Head lamp high beam pilot lamp 27. Emergency steering pilot lamp (*2)
8. Turn signal pilot lamp (right) 28. Meter display pilot lamp
9. Fuel level caution lamp 29. Character display portion
10. Fuel gauge 30. Preheating pilot lamp
11. Central warning lamp 31. Directional selector switch actuation pilot lamp
12. Brake oil pressure caution lamp (*1)
13. Engine oil pressure caution lamp 32. Economy operation display lamp
14. Water separator caution lamp 33. Shift hold pilot lamp (*1)
15. Engine oil level caution lamp (*1) 34. S mode operation pilot lamp
16. Radiator coolant level caution lamp 35. Traction control operation pilot lamp
17. HST oil filter clogging caution lamp 36. Travel speed range selector switch position
18. Air cleaner clogging caution lamp (*1) pilot lamp
19. Parking brake pilot lamp 37. Directional lever position pilot lamp
20. Brake oil temperature caution lamp
*1: Not used by this model

*2: If equipped
6 WA200-6
List of items displayed on monitor 1

Condition for judging that the engine is running:
If 2 or more are met in the following 3 conditions, the engine is judged running when the abnormality in the
CAN communication occurs and the charge level exceeds the specified level.
1. Turning "ON" of the starting switch is recorded (IGN-C signal was entered)
2. Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above
after that)
3. Engine speed is 500 rpm or above
Lamp Lamp period Alarm buzzer Operating condition Buzzer period Priority
w: Intermittent Warning for dangerous Period: 1,600 msec.

Q: ON — condition (error or caution ON: 800 msec. 1
sounds
message is generated) OFF: 800 msec. (duty 50%)
Period: 1,600 msec. Caution for erroneous Period: 240 msec.
A: Intermittent
w: Flashing ON: 800 msec. operation (when an irregular ON: 80 msec. 2
OFF: 800 msec. (duty 50%) sounds operation is done) OFF: 160 msec.
Period: 240 msec.
E: Canceling Set cancellation such as
A: Intermittent ON: 80 msec. sounds calibration (inoperative state) ON: 1,000 msec. (1 time) 3
OFF: 160 msec.
Completion of setting such ON: 100 msec.
E: Separately e: Completion
— as calibration (when normally OFF: 160 msec. 4
set conditions sounds
ended) ON: 100 msec. (1 time)
Detecting Operating condition

time
(sec) Engine stopped Engine is running
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Category No. Item Device Operating condition Remarks
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Turned ON with errors (E03
and E02) of each controller,
When error occurs E E E E E E E E simultaneously displaying the
message on the character
Central
Red
11 Central warning LED display.
warning lamp
For other than above, see
"Operating condition, central
— — — — — —
warning lamp" of other
items.
White
When lamp switch is other
Back light — Back light LED — — — — — —
than "OFF"
White range: 30 – 105°C

Other than below — — — — — — Red range: 105 – 135°C
Pointer:
Movement When the sensor is
1 HST oil
Red
Alarm: 105°C or above 10 1 w Q Q B@CRNS w Q Q B@CRNS disconnected or hot short-

2 temperature
Caution circuited: Max
lamp: LED When abnormality is When sensor was
detected (out of input signal 20 5 — — — DGH1KX — — — DGH1KX disconnected or hot short-
range) circuited: Min
Other than below — — — — — —
White range: 50 – 102°C

Alarm: 102°C or above 3 0 — Q — — Q — Red range: 102 – 135°C
Gauges and Pointer:
meters Movement When the sensor is
3 Engine coolant
Red
Alarm: 105°C or above w Q Q B@BCNS w Q Q B@BCNS disconnected or hot short-

4 temperature
Caution circuited: Max
lamp: LED When sensor was
When abnormality is disconnected or hot short-
— — — CA144 — — — CA144
detected (high temperature) circuited: Min
When abnormality is
— — — CA145 — — — CA145
detected (low temperature)
When engine speed display (selectable with the machine

Engine speed — — — — — — monitor setting)
is selected
Pointer:
5 —
Movement When a communication error
When travel speed display is is detected, the system
Travel speed — — — — — —
selected displays "0".
Other than below — — — — — — Max: 10 z

Min: 85 z
Pointer:
Movement Min. 62 z 10 1 — Q — — Q —
Gauges and 9 When the sensor is grounded:
Red
Fuel level
meters 10 Full
Caution
When abnormality is When sensor was
lamp: LED
detected (input voltage is 4 V disconnected or hot short-
10 2 — — — DJF1KA — — — DJF1KA circuited: Empty
or above and no incoming
IGN-C signal is detected)
WA200-6 7

time
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Operates when charging
Service meter normally at 1 : 1 to the clock — — — — — — Displays various codes and
time
Black
Character items according to the
29 LCD
display machine condition and switch
Converts travel speed pulse operation.
Odometer — — — — — —
into travel distance
x 100 r/min
Green
When engine speed display (setting of a desired value is
Engine speed 0 0 — Q — — Q —
is selected available from the machine
monitor)
Unit 28 LED
km/h or MPH
Green
When travel speed display is (setting of a desired value is
Travel speed 0 0 — Q — — Q —
selected available from the machine
monitor)
When F is selected (neutral
Green Green Green Green Green Green Orange Green

F LED safety is displayed as engine 1 0 A Q Q — Q —
is stopped)
Directional
37 lever N LED When N is selected 0 0 — Q — — Q —
position
When R is selected (neutral
R LED safety is displayed as engine 1 0 A Q Q — Q —
is stopped)
When error occurs in
Items related
When 4th gear speed is communication, condition is
to gear 4 LED 0 0 — Q — — Q —
selected held until starting switch is
shifting
turned "OFF".
Travel When 3rd gear speed is
speed 3 LED 0 0 — Q — — Q —
selected
range
36
selector
switch When 2nd gear speed is
2 LED 0 0 — Q — — Q —
position selected
When 1st gear speed is

1 LED 0 0 — Q — — Q —
selected
When turn signal lever and Hazard lamp operates when
6
Turn signal LED hazard lamp switch signal is 0 0 — Q — — Q — starting switch is turned
8
input "OFF".
When head lamp is set to
Head lamp high high beam (when head lamp
Blue
7 LED 0 0 — Q — — Q —
beam is "ON" and dimmer switch
is "ON")
Normal oil pressure

— — — — — —
(CLOSE)
Below set pressure (OPEN)

(detection time continues)
1 1 — Q — w Q Q
Brake oil and 30 seconds after engine
Red
12 LED is started (no detection time)

pressure
Below set pressure (OPEN)
(detect time continues) and
after 30 seconds elapsed 5 1 — — — w Q Q 2G40ZG
since engine was started
(no detection time)
Normal oil pressure

— — — — — —
(CLOSE)
Engine oil
Red
13 LED
pressure
Other Low oil pressure (OPEN) w Q Q B@BAZG w Q Q B@BAZG
symbols
Normal — — — — — —
Water
Red
14 LED
separator
Water mixing with fuel — Q — CA418 — Q — CA418
Normal coolant level

— — — — — —
(CLOSE)
Radiator
Red
16 LED
coolant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK
Normal (OPEN) — — — — — —
Clogging (CLOSE) (HST oil

temperature 50°C or above
HST oil filter 10 2 — — — — Q — 6091NX
Red
17 LED and no abnormality

clogging detected)
When abnormality is
detected (clogging was KEY
3 — — — DHTCL6 — — — DHTCL6
detected as engine was OFF
stopped)
8 WA200-6

time
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Operation (OPEN) — Q — — Q —
Released (CLOSE) — — — — — —
Red
19 Parking brake LED
Engine is running, parking
brake is operated and the
0 0 — — — A Q Q
directional lever is at any
position other than "N"
Temperature rise (oil

temperature: Min. 120°C 5 5 — Q — — Q —
(alarm)
Temperature rise (1. or 2.)
1. Oil temperature 130°C or To be released if the oil
Brake oil above temperature is detected
Red
20 LED 5 5 w Q Q B@C6NS w Q Q B@C6NS
temperature 2. Oil temperature 125°C or consecutively at lower than
above and travel speed 125°C for 5 sec.
35 km/h or above
When abnormality is
— — — DGR2KB — — — DGR2KB
detected (ground fault)
When abnormality is
detected (disconnection or — — — DGR2KZ — — — DGR2KZ
hot short-circuit)
Alarm buzzer is sounded
Other than below — — — — — — when connection of quick
coupler is reset. Error
Quick coupler
Red
21 LED message is simultaneously
operation
When quick coupler is displayed on the character
0 0 A Q — Remarks A Q — Remarks display.
disconnected
"PIN DISCONNECT"
Normal 0 0 — — — — — —
Error message is displayed on
the character display when
Orange
Cooling fan
22 LED Reverse 0 0 — Q — Remarks — Q — Remarks long as reverse rotation of fan
reverse rotation
is continued.
"COOLING FAN REVERSE"
Selecting reverse rotation 0 0 — w — — w —
Other
symbols
Ordinary — — — — — —
Message is simultaneously
Red
23 Maintenance LED displayed on the character

30 hours or less before display.
maintenance or — Q — E — Q — E
maintenance time
Error message is displayed on
the character display as long
as parking brake is left
Other than below — — — — — — unapplied.
"The alarm continues as long
as starting switch is turned
Parking brake
Red
24 LED "OFF".
reminder
This function can be enabled
when "MECHA" is selected for
When parking brake is left "7. PKG BRAKE" from the
0 0 w Q Q Remarks — — —
unapplied (CLOSE) "Option device selecting
function" of the machine
monitor.
If abnormality is detected
Normal voltage — — — — — — when starting switch is turned
"ON", alarm is continued even
Engine is running, alternator after engine is started.
Battery charge voltage is below the
Red
25 LED 30 1 — — — w Q Q AB00MA
circuit specified level, and no <Voltage hysteresis>
incoming ING-C is present. Judgment for Abnormal o
When abnormality is Normal: 12 V or above
detected (unmatched engine 3 1 w Q Q AB00L6 — — — Judgment for Normal o
condition and the signal) Abnormal: 5 V or below

Oil pressure normal (OPEN) — — — — — — when "ADD" is selected for "2.
EMERG S/T" from the
"Optional device selecting
Steering oil
Red
26 LED 0.5 0 — Q — — Q — function" of the machine

pressure
monitor.
Low oil pressure (CLOSE) *: The function is reset
(*) immediately when engine
3 — — — w — Q DDS5L6
1 is stopped.
Oil pressure normal (OPEN) 0 0 — Q — — Q — when "ADD" is selected for "2.
Green
Emergency EMERG S/T" from the

27 LED
steering "Optional device selecting
Low oil pressure (CLOSE) — — — — — — function" of the machine
monitor.
WA200-6 9

time
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Red
30 Preheating LED
When preheater is turned
0 0 — Q — — Q —
ON
Other than below 0 0 — — — — — —
Green
Economy
32 LED
operation
Economy mode operation 0 0 — Q — — Q —
Other
symbols
Green
S mode
34 LED The lamp goes off when
operation
S mode operation is traction control is reset from
0 0 — Q — — Q —
selected max. traction switch. When
traction control is reset with
max. traction switch, the lamp
Other than below — — — — — — is lit again when directional
Green
Traction control lever position is switched.
35 LED
operation
Traction control operation is
0 0 — Q — — Q —
turned on
10 WA200-6
Machine monitor operation switch 1
1. Machine monitor mode selector switch 1

2. Machine monitor mode selector switch 2
WA200-6 11
Setting of machine monitor
1. Spare rotary switch (SW1)

4. Spare dip switch (SW5-1)
a It is prohibited to change setting of spare rotary switch and DIP switch.
Troubleshooting function
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
12 WA200-6
Character display function

q Machine monitor display and setting can be changed by using the character display.
q The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.
*1: When an ID entered from the "ID entry" screen is once approved, display changes directly to the "Select
function" screen without displaying the "ID entry" screen until the starting switch is turned "OFF".
WA200-6 13
Operator mode functions 1

Self-check screen (0th layer)
q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON".
q During a self-check, entry through the machine monitor operating switch is not accepted.
q After ending the self-check, the self-check screen automatically moves to 1st layer.
Normal screen (1st layer)

q If the item of "13. RPM/SPEED" is set to "ADD" in the "Optional device selecting function" of machine
monitor, engine speed is displayed to the character display when the travel speed is displayed at the
center of the monitor.
q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the charac-
ter display.
q Pressing the "U" switch changes the screen to the 2nd layer.
1. Engine speed display

2. Travel speed display
A. In the case of "km/h" display
B. In the case "MPH" display
a When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character
display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in
"km/h".
14 WA200-6
Failure code screen (1st layer)

q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code
screen.
q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item
of higher priority downward. If items have the same priority, the item that occurred most recently will be
displayed first.
Example of a failure code screen (simultaneously occurring errors: DX16KA, B@BCZK and CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
WA200-6 15
Display of functions opened to the operator (2nd layer or below)

q Certain menus are not displayed unless the items in the "Optional device selecting function" of the
machine monitor are set.
q Pressing "U" switch allows selecting each menu.
q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not
pressed more than 60 seconds in the screen display of each menu.
q The language will be displayed as set in the Language selection function.
a See the "Operation and maintenance manual" for details of each menu.
*1: These menus are displayed when "ADD" is selected for "13. RPM/SPEED" item from the "Optional
device selecting function" of the machine monitor.
*2: These menus are displayed when "ADD" is selected for "12. RPM/OPT" item from the "Optional device
selecting function" of the machine monitor.
k It is prohibited to select "ADD" for "12. RPM/OPT" from the "Optional device selecting function"
of the machine monitor in the regions where the applicable law requires to display the travel
speed.
16 WA200-6
Service mode functions 1

q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.
Procedure for switching to Service Mode

1. Checking of the screen display 3. ID input and confirmation
Check that the character display is set to the Operate the machine monitor mode selector
1st layer screen in the operator mode. switches 1 and 2 and enter ID. (ID: 6491)
2. Display of ID input initial screen

Pressing " u " switch and "<" switch simulta-
neously for 5 seconds or more displays the ID
entry initial screen.
a Pressing down the 2 switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the switches.
1) The cursor (C) is located at the highest-

order digit. Pressing "<" or ">" switch
changes the value of this digit in the range
of "0" to "9".
2) Press "U" switch at the target value to val-
idate it.
a The cursor moves to the 2nd digit
position.
3) Confirm the values for the 2nd digit and
onward following the same procedure.
a If you have entered a wrong value to
a p os it io n whe n the c ur s or was
located at any position other than the
highest-order digit, press " t" switch
to move the cursor to the highest-
order digit to enable to input correct
value. In this case, the values already
entered remain on the screen
unchanged.
a Pressing "t" switch when the cursor
is located at the highest-order digit,
the screen returns to the "1st layer" of
the operator mode.
a If switch is not operated more than 60
seconds on the "ID entry" screen, it
automatically returns to the "1st layer"
screen of the operator mode.
4) If ID is acknowledged upon confirming the
4th digit, the screen changes to the "Elec-
trical system failure history" selector
screen.
WA200-6 17
Service mode menu
a Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same
menu.
a Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.
18 WA200-6
Electrical system failure history display Real-time monitoring function (REAL-TIME

function (ELECTRIC FAULT) MONITOR)
a "**" field displays total number of the failure q This function is used to check on the input/out-
history currently recorded. (max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
a For the operating procedure of this function,
q The history is used to check on the electrical see "Special functions of machine monitor
system failures of each controller saved in the (EMMS)" in Testing and adjusting.
machine monitor. After repairing the failure
content and verifying normal function, the fail-
ure history may be erased.
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
Mechanical system failure history display Engine reduced-cylinder function (CYLINDER

function (MACHINE FAULT) CUT-OUT)
a "**" field displays total number of the failure q This function is used for the purpose of speci-
history currently recorded. (max. 20 histories to fying cylinder having defective combustion by
be stored) stopping fuel injection to each cylinder from the
fuel injector.
q The history is used to check on the mechanical a For the operating procedure of this function,
system failures of each controller saved in the see "Special functions of machine monitor
machine monitor. (EMMS)" in Testing and adjusting.
WA200-6 19
No injection cranking function (NO INJECTION) Maintenance monitoring function (MAINTE-

NANCE MONITOR)
q Before restarting engine after a long-term stor-

ing of the machine, this function is used to q This function is used for changing the filter and
lubricate the engine internally. oil replacement timing and making ON/OFF
a For the operating procedure of this function, selection of this function.
see "Special functions of machine monitor a For the operating procedure of this function,
(EMMS)" in Testing and adjusting. see "Special functions of machine monitor
Adjustment function (TUNING) Operating information display function

(OPERATION INFO)
q This function is used for correcting and adjust-

ing the installation errors and manufacturing q This function is used for displaying fuel con-
dispersion of the sensors, solenoid valves, etc. sumption per operating hour.
Function for changing control characteristics is a For the operating procedure of this function,
provided on user request. see "Special functions of machine monitor
These functions are also used when sensors, (EMMS)" in Testing and adjusting.
valves and controllers are replaced or added.
20 WA200-6
Optional device selecting function (OPTIONAL Model selection function (MACHINE)

SELECT)
q This function is used for displaying or changing

q This function is used for verifying the installed the setting of model information (machine
state of optional devices or when changing name).
their setting. a For the operating procedure of this function,
This function is also used for installing or see "Special functions of machine monitor
removing optional devices. (EMMS)" in Testing and adjusting.
a For the operating procedure of this function, a The figure shows when "WA250" is selected.
Machine serial number input function Initialize function (INITIALIZE)

(MACHINE No. SET)
q This function is used to set the machine moni-

q This function is used for displaying or entering tor to the state set when delivered.
the serial number of machine. a Since this function is specially handled by the
Serial number of the set machine is used for factory, no modification is allowed.
controlling the machine.
WA200-6 21
AMP070-20P[CN-L24]
Pin No. Specifications I/O Group Form of use Signal name Remarks
1 (NC) — — — —
2 (NC) — — — —
3 (NC) — — — —
Constant power
4 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Constant power
5 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Power supply
6 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
Power supply
7 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
8 (NC) — — — —
9 GND I — GND GND
10 GND I — GND GND

D_OUT_3
11 O A D/O sink ECSS relay If equipped
(+24 V, sink 200 mA)
D_OUT_2
12 O A D/O sink Back-up lamp
(+24 V, sink 200 mA)
D_OUT_1
13 — — — —
(NC)
D_OUT_0
14 O A D/O sink Alarm buzzer
(+24 V, sink 200 mA)
15 (NC) — — — —
16 (NC) — — — —
22 WA200-6
AMP070-18P(1)[CN-L25]
D_IN_0
1 I B D/I (+24 V) Head lamp
(24 V, 5 mA)
D_IN_2
2 I B D/I (+24 V) Starting switch C signal
(24 V, 5 mA)
3 (NC) — — — —
D_IN_6
4 I B D/I (+24 V) Quick coupler If equipped
(24 V, 5 mA)
D_IN_8
5 I B D/I (+24 V) ECSS switch If equipped
(24 V, 5 mA)
6 (NC) — — — —
D_IN_12
7 I C D/I (+24 V) Turn signal lamp, right
(NSW24 V, 5 mA)
D_IN_14
8 I C D/I (+24 V) U switch
(NSW24 V, 5 mA)
9 GND O — GND Signal GND
D_IN_1 Cooling fan automatic reverse
10 I B D/I (+24 V)
(24 V, 5 mA) rotation switch (manual)
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
D_IN_9 Cooling fan automatic reverse
14 I B D/I (+24 V) If equipped
(24 V, 5 mA) rotation switch (automatic)
15 (NC) — — — —
D_IN_13
16 I C D/I (+24 V) Turn signal lamp, left
(NSW24 V, 5 mA)
D_IN_15
17 I C D/I (+24 V) t switch
(NSW24 V, 5 mA)
A_IN_0
18 I H A/I Alternator L signal
(0 – 30 V)
AMP070-12P(1)[CN-L26]
D_IN_16
1 I D D/I (GND) Brake oil pressure
(24 V/GND, 5 mA)
2 (NC) — — — —
D_IN_20
3 I D D/I (GND) (air cleaner clogging)
(24 V/GND, 5 mA)
D_IN_22
4 I D D/I (GND) Traction control switch (S mode)
(24 V/GND, 5 mA)
D_IN_24
5 I E D/I (GND) HST oil filter clogging
(24 V/GND, 5 mA)
6 GND O — GND Sensor ground
D_IN_17
7 I D D/I (GND) (ECSS cut off switch)
(24 V/GND, 5 mA)
D_IN_19
8 I D D/I (GND) (service mode 2 and 3)
(24 V/GND, 5 mA)
D_IN_21
9 I D D/I (GND) (ECSS cutoff switch dummy)
(24 V/GND, 5 mA)
10 (NC) — — — —
D_IN_25
11 I E D/I (GND) (optional switch)
(24 V/GND, 5 mA)
A_IN_1
12 I H A/I Clearance lamp and tail lamp
(0 – 30 V)
WA200-6 23
AMP070-18P(2)[CN-L27]
D_IN_26
1 I E D/I (GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28 Parking brake left-unapplied
2 I E D/I (GND)
(24 V/GND, 5 mA) prevention
D_IN_30
3 I E D/I (GND) Normal emergency steering If equipped
(24 V/GND, 5 mA)
4 (NC) — — — —
D_IN_34
5 I F D/I (GND) Dimmer switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/I (GND) Parking brake dummy
(24 V/GND, 5 mA)
D_IN_38
7 I G D/I (GND) < switch
(24 V/GND, 5 mA)
8 (NC) — — — —
9 GND O — GND GND

D_IN_27
10 I E D/I (GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/I (GND) (engine oil level)
(24 V/GND, 5 mA)
12 (NC) — — — —
13 (NC) — — — —
D_IN_35 Parking brake left-unapplied
14 I F D/I (GND)
(24 V/GND, 5 mA) prevention dummy
D_IN_37
15 I G D/I (GND) > switch
(24 V/GND, 5 mA)
D_IN_39
16 I G D/I (GND) Operation of emergency steering If equipped
(24 V/GND, 5 mA)
17 (NC) — — — —
18 (NC) — — — —
AMP070-12P(2)[CN-L28]
A_IN_2
1 I J A/I Fuel level sensor
(high-resistance input)
A_IN_4
2 I J A/I HST oil temperature sensor
3 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
6 GND O — GND GND

A_IN_3
7 I J A/I Brake oil temperature sensor
8 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
11 GND O — GND (GND)
12 (NC) — — — —
24 WA200-6
AMP070-12P(3)[CN-L29]
1 (NC) — — — —
2 (NC) — — — —
3 CAN (+) I/O P CAN CAN (+)
4 (NC) — — — —
5 (NC) — — — —
6 GND O — GND GND
7 (NC) — — — —
8 CAN (–) I/O P CAN CAN (–)
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
AMP070-14P[CN-L30]
1 (NC) — — — —
2 (NC) — — — —
3 (NC) — — — —
4 (NC) — — — —
5 (NC) — — — —
6 (NC) — — — —
7 (NC) — — — —
8 (NC) — — — —
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
14 (NC) — — — —
WA200-6 25
AMP040-8P
Do not connect wiring
1 (NC) — — — —
harness on machine
2 (NC) — — — —
harness on machine
3 (NC) — — — —
harness on machine
4 (NC) — — — —
harness on machine
5 (NC) — — — —
harness on machine
6 (NC) — — — —
harness on machine
7 (NC) — — — —
harness on machine
8 (NC) — — — —
harness on machine
Setting switches (On circuit board)

Switch
Specifications I/O Group Form of use Signal name Remarks
No.
1 16 Posi rotary switch 1 I — — (spare)
1 26 Posi DIP switch 1 I — — (spare)

5

6
26 WA200-6
WA200-6 27
SEN03258-00

©2007 KOMATSU
All Rights Reserved
28
SEN03259-00
WA200-6
WA200-6 70001 and up

Electrical system, Part 2

Electrical system (HST controller system) ...................................................................................................... 2
HST controller ............................................................................................................................................... 18
ECSS system................................................................................................................................................ 19
KOMTRAX system........................................................................................................................................ 20
Engine starting circuit.................................................................................................................................... 22
Engine stopping circuit.................................................................................................................................. 24
Preheating circuit .......................................................................................................................................... 25
Engine output derating function .................................................................................................................... 26
Automatic warm-up function ......................................................................................................................... 26
Parking brake circuit ..................................................................................................................................... 28
Max. traction switch ...................................................................................................................................... 30
Sensor........................................................................................................................................................... 31
WA200-6 1
Electrical system (HST controller system) 1
a Except where otherwise specified, the displayed travel speed in this document represents the one when
17.5-25 tire is worn.
Input and output signals diagram

Travel speed range selector switch Ao o A HST motor 1 solenoid
Operating switch input
Variable shift control switch Ao o D HST motor 2 solenoid relay
Traction control switch Do o A Clutch solenoid
Solenoid output
Directional lever (F, N, R) Do o A Cooling fan motor flow rate control EPC valve
Parking brake lever intermediate switch Do o D Cooling fan motor reverse rotation solenoid relay
Parking brake lever bottom switch Do o D Directional solenoid (F, R)
Speed sensor A Po o D HST controller power holding relay

Sensor input
Speed sensor B Po o D HST safety relay
HST oil pressure sensor Ao o C Throttle upper limit (Eng_con)
Engine speed (Eng_con) Co o C Throttle lower limit (Eng_con)
Accelerator pedal angle (Eng_con) Co o C Automatic warm-up cancel (Eng_con)
Coolant temperature (Eng_con) Co

Monitor display information (Eng_con)
Boost temperature (Eng_con) Co o C (Failure code, real-time monitor, pilot lamp, alarm
buzzer, etc.)
HST controller
CAN output
Monitor display information (Eng_con)
(Failure code, real-time monitor, pilot lamp, alarm Co o C Travel speed (Mon)
buzzer, etc.)
o C ECSS operation command (Mon)
HST oil temperature (Mon) Co o C Back-up lamp operation command (Mon)
Cooling fan manual reverse rotation (Mon) Co o C Failure code signal (Mon)
CAN input
Cooling fan automatic reverse rotation (Mon) Co o C Real-time monitor signal (Mon)
ECSS (Mon) Co o C Pilot lamp signal (Mon)
Traction control S mode (Mon) Co o C Load frequency information (KOMTRAX)
Model selection (Mon) Co
Option device selecting (Mon) Co
Automatic fan switching cycle to reverse rotation

Co
(Mon)
Reverse rotation duration (Mon) Co
Traction control level (A, B, C) (Mon) Co
HST selector (A, B) (Mon) Co
Tire selection (Mon) Co
Service meter (Mon) Co
Eng_con: Engine controller

Mon: Machine monitor
KOMTRAX: KOMTRAX terminal
A: Analog signal
D: Digital signal
P: Pulse signal
C: CAN signal
2 WA200-6
HST controller gear shifting control function 1

Gear shifting function
q Receiving the travel speed range selector signal and the variable shift control signal, this function con-
trols HST motor 1, HST motor 2 and transfer clutch in such that the maximum travel speed suited for the
given state is produced.
Selected Variable shift control
Travel speed range Clutch solenoid HST motor 1 HST motor 2
speed signal input voltage
(km/h) output solenoid output solenoid output
range (V)
0 – 13
1st (depends on the variable ON MAX – MID Fixed to MAX (ON) 0.9 – 4.1
shift control signal)
2nd 0 – 13 ON MAX – MID Fixed to MAX (ON) —
3rd 0 – 18 ON, OFF MAX – 0 Fixed to MAX (ON) —
Fixed to MAX –
4th 0 – 38 ON, OFF MAX – 0 —
Variable (ON, OFF)

and travel speed (A) for starting transfer clutch
switching modulation
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
8 km/h 8 – 10 km/h 10 km/h
Disengaged (C)
Disengaged o
7 km/h 7 – 9 km/h 9 km/h
Engaged (B)

and travel speed (A) for switching HST motor 2
capacity
HST motor 2 Accelerator pedal angle (%)
capacity 0 – 65 65 – 90 90 – 100
Free (C) 8 km/h 8 – 10 km/h 10 km/h
Max. fixed (D) 9 km/h 9 – 11 km/h 11 km/h
WA200-6 3
1. HST pump 5. Clutch solenoid valve

2. HST motor 1 6. HST motor 1 solenoid valve
3. HST motor 2 7. HST motor 2 solenoid valve
4. Transfer clutch 8. Transfer output shaft
Gear shifting display function

q The HST controller displays the state of input signals related to gear shift on the monitor by sending
them to the machine monitor via network.
1. Directional indicators
The directional lever position pilot lamps of the machine monitor indicate the state of the directional
lever based on the input data to the HST controller.
When the directional lever is at the neutral position and no input signal is sent to the HST controller, all
the directional lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the HST controller by accident, two directional lever position
pilot lamps of the machine monitor may turn on at the same time.
As the directional lever is set to "R (reverse)" the HST controller activates the backup lamp relay to light
the reverse lamp and sound the back-up alarm.
2. Speed range indicator

The travel speed range selector switch position pilot lamp of the machine monitor displays the state of
the travel speed range selector switch being sent to the HST controller.
Variable shift control system

q When the travel speed range selector switch is set to the 1st speed, the variable shift control signal
allows adjusting the maximum speed in the range of 4 - 13 km.
4 WA200-6
Transfer clutch control function

q In order to reduce impacts resulting from connecting the transfer clutch or to prevent inadequate torque
due to delayed connection of the transfer clutch, this function adjusts the clutch oil pressure to an opti-
mum level for the machine state (travel speed, travel load, HST oil temperature, directional lever and
accelerator opening ratio) by referencing the modulation table of the HST controller.
q In order to reduce lack of the torque, this function maintains the modulation control when the clutch is
released.
Traction control function

q Receiving the traction control signal, this function derates the maximum capacity of HST motor 1 to con-
trol the traction force.
q "Traction level selecting function" of the machine monitor allows selecting a desired traction force out of
3 levels (A, B and C).
q The traction control operation pilot lamp remains turned on as long as the traction control operation is
continued.
a For the operating method of this function, see the "Operation and maintenance manual".
S mode function
q Receiving the S mode signal, this function reduces the maximum capacity of HST motor 1 and the upper
limit of the throttle opening ratio in order to secure an optimum drive force for the dozing work on very
slippery road surface (on the snow-covered road, sandy terrain, etc.).
q This function restricts sudden start in forward travel by reducing skidding of tires through control of the
drive force. And by securing smooth start of the machine, this function offers enhanced operating perfor-
mance.
q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode opera-
tion is continued.
a The traction force control in the S mode is enabled when the directional lever is set to the "forward" posi-
tion and the machine is traveling forward or stopped.
a For the operating method of this function, see the "Operation and maintenance manual".
Features
Switch
Pilot lamp Traction level Road Guideline
position Traction Material
condition
1
OFF 1
(OFF)
Suitable for loading work. Improves work
Powerful Hard-packed Un-slippery efficiency and provides antislip by selecting
2A
I I I traction level depending on material and road
O O O conditions.
2 2
2B Soft Loose Slippery
(ON) (ON)
Select when operating with the special
2C
attachment which requires small traction force.
Provides the best driving force on very
Select when the machine tends to slip when
3 3 slippery road surfaces covered by snow,
3 forwarding, such as on snow or sand covered
(S mode) (ON) sand, etc. Prevents the tires from slipping to
road surface.
facilitate work.
WA200-6 5
The maximum traction force available when the

travel speed range selector switch is set to
"1st" and the traction control switch is set to
"ON"
q When the travel speed range selector switch

(1) is set to "1st" and the variable shift control
switch (2) is turned fully to the left, setting the
traction control switch to the ON position does
not reduce the maximum traction force. In this
case, the maximum traction force remains at
the same level as when the traction control
switch is set to the "OFF" position.
q As clockwise turning of the variable shift con-
trol switch (2) is continued, the traction force
approaches the maximum traction force being
set from the "Traction level selecting function"
of the machine monitor.
q It is possible to obtain the maximum traction
force, which has been set from the traction
control switch and "Traction level selecting
function" of the machine monitor, by turning the
variable shift control switch (2) fully to the right.
6 WA200-6
Max. traction function

q Pressing the max. traction switch while the traction control is "ON" or the S mode is selected cancels the
traction control or the S mode temporarily to increase the maximum drawbar pull.
q If the directional lever or directional selector switch is operated, or the max. traction switch is pressed
again while the traction control or S mode is cancelled from the max. traction switch, the traction "ON"
state or S mode is restored.
q As long as the traction control or S mode is cancelled from the max. traction switch, the traction control
operation pilot lamp or S mode operation pilot lamp of the machine monitor remains turned off.
a Holding down the max. traction switch for a second or longer cancels the traction control or S mode as
long as it is held down. The traction control or S mode is restored at the moment the switch is released.
a If the traction control is sequentially turned "ON" and "OFF" in less than a second, the traction control or
S mode is cancelled temporarily just like the max. traction switch is held down for less than a second.
1. Traction control switch

2. Max. traction switch
3. HST controller
4. Machine monitor
a. Traction control switch signal

b. S mode signal
c. CAN signal
WA200-6 7
HST controller protection function 1
HST motor 1 overrun prevention function 1

q If the 1st or 2nd speed is selected while the machine is traveling at a high speed with the travel speed
range selector switch being set to the 3rd or 4th, the transfer clutch is engaged during the high speed
travel, preventing HST motor 1 to overrun beyond the allowable rotating speed.
q In order to prevent the overrun, this function disables the gear shift from the 3rd or 4th to the 2nd or 1st
when the transfer clutch is released.
q As above gear shift is disabled, this function generates "OVERRUN PROTECT" message on the
machine monitor character display and activates the alarm buzzer.
q This error status is reset as the transfer clutch is engaged or the travel speed range selector switch is
set to an allowable gear shift position.
a Above error message is not sent to KOMTRAX terminal.
Gear shift operation Behavior after gear shift
Switch position Switch Actual speed
State of transfer Display of
before gear position after range after Remarks
clutch after gear shift message
shift gear shift gear shift
2nd 2nd
Gear shift available independent
1st Connected 3rd 3rd Not displayed
of traveling speed
4th 4th
1st 1st
Gear shift available independent
2nd Connected 3rd 3rd Not displayed
of traveling speed
4th 4th
1st 1st
Connected 2nd 2nd Not displayed
4th 4th Gear shift to 1st or 2nd becomes
3rd available only when the clutch is
(*1) 1st 3rd engaged.
Displayed
Other than the 2nd 3rd
connected state 4th 4th Not displayed
1st 1st
Connected 2nd 2nd Not displayed
3rd 3rd Gear shift to 1st or 2nd becomes
4th available only when the clutch is
(*1) 1st 3rd engaged.
Displayed
Other than the 2nd 3rd
connected state 3rd 3rd Not displayed
*1: The clutch is released including the ongoing clutch connection modulation (*2) and clutch release modulation state.
*2: It indicates the period 1.2 seconds after the clutch connection modulation has been started while the machine is
traveling at 7 up to 9 km/h.
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switch-
ing modulation
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
8 km/h 8 – 10 km/h 10 km/h
Disengaged (B)
Disengaged o
7 km/h 7 – 9 km/h 9 km/h
Engaged (C)
8 WA200-6
HST motor 1 overrun prevention function 2

q Downhill travel at 1st or 2nd gear speed tends to allow the machine to increase the travel speed. This
function prevents the rotational speed of HST motor 1 goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function controls the HST motor 1 capacity to the allowable max-
imum if the travel speed goes beyond 14 km/h.
Travel speed control function

q Downhill travel at a high speed tends to allow the machine to exceed the speed limit because the rota-
tional speed of HST motor 2, axle and engine goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function fixes the HST motor 2 capacity to the allowable maxi-
mum if the travel speed goes beyond 36 km/h.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the
q This error state is reset as the travel speed goes below 35.6 km/h or less.
a Above error message is not sent to KOMTRAX terminal.
Engine overrun prevention function

q If the HST motor 2 capacity reaches its allowable rotating speed when the machine travels downhill at a
high speed, the HST pump and engine rotation becomes high speed. This function prevents the HST
motor 2 to overrun beyond the allowable rotating speed.
q This function prevents the HST motor 2 solenoid valve to be set to "ON" (fixed to MAX) when the travel
speed is more than 30 km/h and the engine speed is more than 2,925 rpm. If the HST motor 2 solenoid
valve is already set to "ON", the solenoid valve is forcibly set to "OFF" to prevent the HST pump and
engine from overrun.
q This function is canceled when the engine speed goes below 2,825 rpm.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the
Neutralizer function
q When the parking brake lever is pulled (the switch at the bottom of the parking brake lever is "OFF"), this
function, independent of the directional lever position, holds HST pump at the neutral in order to prevent
dragging of the parking brake.
WA200-6 9
Economy operation pilot lamp function 1

q In order to prompt the operator for the low fuel consumption operation, this function lights up the econ-
omy operation pilot lamp as long as the low fuel consumption operation is continued.
q The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at
less than 75% for 0.5 seconds or longer.
q The economy operation pilot lamp can be constantly turned off by selecting "NO ADD" for "4. ECO
LAMP" item from the "Optional device selecting function" of the machine monitor.
a For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.
10 WA200-6
Cooling fan control function 1
1. HST controller Input and output signals

2. Machine monitor HST controller
3. Engine controller a. CAN signal
4. Cooling fan pump b. Cooling fan motor flow rate control signal
5. Cooling fan motor c. Cooling fan reverse signal
5a. Cooling fan motor flow rate control EPC valve
5b. Cooling fan reverse solenoid valve Machine monitor
6. Cooling fan reverse switch d. Cooling fan automatic reverse signal
7. Machine monitor mode selector switch 1 e. Cooling fan manual reverse signal
8. Machine monitor mode selector switch 2 f. CAN signal
9. Cooling fan reverse solenoid valve relay g. "U" switch signal
10. HST oil temperature sensor h. "t" switch signal
11. Boost pressure and oil temperature sensor i. ">" switch signal
12. Coolant temperature sensor j. "<" switch signal
13. Engine speed sensor k. HST oil temperature signal
14. Engine
15. Radiator Engine controller
l. CAN signal
m. Boost pressure and temperature signal
n. Engine speed signal
o. Coolant temperature signal
WA200-6 11
Fan control
q Employment of the hydraulically driven cooling fan and the control of the flow rate of the hydraulic motor
allow reducing the horsepower loss and noises as well as cutting the warm-up operation time in a low
temperature environment.
q Engine speed, coolant temperature and boost air temperature received by the engine controller, and the
information of HST oil temperature received by the machine monitor are sent to the HST controller via
the network.
q Based on the received information, the HST controller sends the signal current to the cooling fan motor
flow rate control EPC valve in order to set the fan speed to a level suitable for the respective tempera-
ture levels and the engine speed.
Fan speed in accordance with temperature
*1: The target fan speed is determined based on the coolant temperature, HST oil temperature or boost air
temperature data, whichever is the highest.
*2: Within this range, the fan speed is set according to the coolant temperature, HST oil temperature and
boost air temperature.
*3: When the boost air temperature is at the lower limit or when the HST oil temperature is low, the fan
speed is decreased to increase the oil and coolant temperature (heater spurting out temperature) and
cut the warm-up operation time.
(the fan speed in this area is controlled based on the hysteresis of each temperature.)
12 WA200-6
Control at start of engine

q In order to protect the fan from being stopped by low oil temperature or settled snow or dusts, the fan
speed is temporarily increased immediately after the engine is started to aid start of the fan rotation.
q After the basic control is turned on, normal fan control is carried on based on the procedure described in
the section of "Fan speed in accordance with temperature".
a The fan control (derating of the minimum fan speed) at start of the engine is conducted only once after
the starting switch has been set to "ON". When, however, the starting switch was turned "OFF" once
and then turned "ON" again, the control is implemented one more time if the control starting conditions
are met.
The control (derating of the minimum fan speed) at start of engine is carried out if every condition in the fol-
lowing table is met.
Condition 1 Starting switch is turned "ON".
Condition 2 Engine speed is 700 rpm or above.
Engine is rotating forward.

Condition 3 [above, however, does not apply as a condition if the controller recognized that switching in the rotating
direction is taking place.]
Condition 4 After the starting switch is turned "ON", the control at start of engine has not been carried out yet.
*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air
temperature is 20°C or above.
Point A: Starting switch is turned "ON" (when engine is stopped)

Point B: Control starting conditions are met
Area C: Minimum fan speed is restricted
Area D: Basic control is turned on
WA200-6 13
Fan reverse rotation function

q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation solenoid valve of the cooling fan motor is activated, reverse rotating the fan.
1. Fan manual reverse rotation function

The operator can select the desired fan rotation direction by pressing the fan reverse rotation switch to
"MANUAL" for 0.5 seconds or longer.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is
reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on
blinking until the preparation for switching is completed.
As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restrict-
ing signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the
switching is underway. Above control, however, is not applicable when the HST oil temperature is 30°C
or above.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is con-
tinued.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch was set to "MANUAL" for 0.5 seconds or longer.
Condition 2 Engine speed over 500 rpm and below 1,200 rpm.
(*1) [above is required to prevent generation of peak pressure in the process of switching the direction.]
Coolant temperature is below 90°C.
Condition 3
[above is required to prevent overheating.]
HST oil temperature is below 95°C.
Condition 4
Boost air temperature is below 70°C.
Condition 5
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
Condition 6 500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1 While the fan is rotating reverse, the fan reverse switch was again set to "MANUAL" and the engine
(*1) speed went to below 1,200 rpm.
Condition 2 After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than
(*1) 1,200 rpm.
Condition 3 The engine has stopped.
*1: The engine speed-related requirement (1,200 rpm) is exempted when the HST oil temperature is
30°C or above.
2. Overheat prevention function

If overheat in the coolant temperature, HST oil temperature or boost air temperature was recognized
while the fan was rotating reverse, the reverse rotation is forcibly stopped and the forward rotation is
turned on in order to increase the air flow to the radiator.
3. Fan speed during reverse rotation

While the reverse fan rotation is continued, this function sets the fan speed to the maximum by cutting
off the command current (sets the command current to 0 mA) to the fan motor flow rate control EPC
valve.
Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the
cleaning work easier.
14 WA200-6
4. Fan automatic reverse rotation function

(if equipped)
Setting the fan reverse rotation switch to "AUTO" allows changing the fan rotation direction switching
cycle and the reverse rotation duration at a specific interval.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is
reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on
blinking until the preparation for switching is completed.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is con-
tinued.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set to "AUTO".
Coolant temperature is below 90°C.

Condition 2
HST oil temperature over 30°C and below 95°C.
Condition 3
[the upper limit of 95°C is required to prevent overheating.]
Boost air temperature is below 70°C.
Condition 4
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
Condition 5 500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
Condition 6 The fan rotation direction switching cycle or the specified reverse rotation duration has elapsed.
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
After the fan reverse rotation switch has been set to any position other than "AUTO" during the
Condition 1
reverse fan rotation, the HST oil temperature reached 30°C or above.
After the fan rotation direction switching cycle or the specified reverse rotation duration has elapsed,
Condition 2
the HST oil temperature reached 30°C or above.
Condition 3 The engine has stopped.
5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
(if equipped)
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items "Adjustment of interval of fan automatic reverse
operation" and "Adjustment of continuance of fan automatic reverse operation" with the adjusting func-
tion of the machine monitor.
a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and
adjusting.
WA200-6 15
System circuit diagram 1
a Items marked with "*1" in drawing may or may not installed.
16 WA200-6
WA200-6 17
HST controller 1
DEUTSCH-40P [CN-HST]
Pin Input/Output Pin Input/Output
Signal name Signal name
No. signal No. signal
1 VB (controller power) Input 21 GND (controller GND) —
2 Starting switch ACC signal Input 22 HST sensor power 5V Input
3 Wake up Input 23 Travel speed adjusting dial Input
4 Directional selector switch F Input 24 Directional selector switch R Input
5 Directional lever N Input 25 Directional selector switch operating switch Input
6 Parking brake lever intermediate switch Input 26 Speed sensor A Input
7 HST controller power holding relay Output 27 HST motor 2 solenoid relay Output
8 NC — 28 CAN0_H Input/Output
9 Clutch solenoid Output 29 Cooling fan motor flow rate control EPC Output
10 HST pump F solenoid Output 30 VIS (solenoid power) Input
11 VB (controller power) Input 31 GND (controller GND) —
12 Starting switch ACC signal Input 32 GND (sensor GND) —
13 Alternator L signal Input 33 HST oil pressure sensor Input
14 Directional selector switch N Input 34 Directional lever F Input
15 Directional lever R Input 35 Traction control switch Input
16 Parking brake lever bottom switch Input 36 Speed sensor B Input
17 HST safety relay Output 37 Cooling fan motor reverse rotation solenoid relay Output
18 NC — 38 CAN0_L Input/Output
19 HST motor 1 solenoid Output 39 Travel speed range selector switch Input
20 HST pump R solenoid Output 40 SOL_COM (solenoid common GND) —
18 WA200-6
ECSS system 1
(if equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
1. HST controller Operation

2. Machine monitor q The operating condition of ECSS is as follows.
3. ECSS switch
ECSS operation
4. ECSS relay ECSS switch Travel speed [km/h]
signal
5. ECSS solenoid valve
OFF 0 – Max.
6. Speed sensor OFF
(*2) Max. 4
ON
Input and output signals (*1) Min. 5 ON
HST controller
a. Travel speed signal A
b. Travel speed signal B
c. CAN signal
Machine monitor
d. CAN signal
e. ECSS switch "ON" signal
f. ECSS operation signal
Outline
q When the machine travels at high speed, the
damping effect of the accumulator charged
with high-pressure gas and the automatic con-
trol of the lift cylinder circuit relief pressure ECSS switching point A B
under each travel condition damp the vertical
movement of the work equipment and reduce (*2) (*1)
Travel speed [km/h]
rocking of the chassis. As a result, the operator 4 5
comfort is improved, spillage of material is pre-
*1. It is allowed to select any travel speed at the
vented, and the working efficiency is improved.
ECSS switching point (B) in the range of 5 to 8
km/h by adjusting the items "Adjustment of
Setting method
ECSS operation travel speed" with the adjust-
q The ECSS can be enabled only when "ADD" is ing function of the machine monitor.
selected for "5. E.C.S.S." item from the *2. The travel speed available at ECSS switching
"Optional device selecting function" of the point (A) is obtained by deducting 1 km/h from
machine monitor. that available at the switching point (B)
a For the setting procedure, see "Special func- (namely, 4 - 7 km/h).
tions of machine monitor (EMMS)" in Testing a For the adjustment procedure, see "Special
and adjusting. functions of machine monitor (EMMS)" in Test-
ing and adjusting.
WA200-6 19
KOMTRAX system 1
(if equipped)
q KOMTRAX terminal transmits various machine information by use of the radio communication. The
KOMTRAX operator is allowed to reference these information in the office and offer them to the cus-
tomer through various services.
a When offering the information to the customer, it is required to separately implement the KOMTRAX
system station opening procedure.
The information transmitted from the KOMTRAX terminal includes the following.
1. Traveling map
2. Service meter
3. Position information
4. Error history
20 WA200-6
KOMTRAX terminal 1
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-L80]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN0_L Input/Output 27 Starting switch C signal Input
8 CAN0_H Input/Output 28 Alternator L signal Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch ACC signal Input
17 NC — 37 Power supply GND —
18 NC — 38 Power supply GND —
19 NC — 39 Constant power supply (24 V) Input
20 Immobilize signal Output 40 Constant power supply (24 V) Input
Outline
q The KOMTRAX terminal can send information
via wireless communication antenna, acquiring
various information of the machine from the
network signal in the machine and the input
signal. Also, the terminal incorporates CPU
(Central Processing Unit) and provide the wire-
less communication function and the GPS
(Global Positioning System) function.
q There are the LED lamp and the 7-segment
indicator lamp in the display area, and these
lamps are used for the testing and the trouble-
shooting.
WA200-6 21
Engine starting circuit 1
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Slow-blow fuse secure safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the
5. Fuse box 2 directional lever is at any position other
6. Starting switch than N (neutral).
7. Directional lever
8. Neutral safety relay 2. The KOMTRAX engine cut-out circuit is
9. KOMTRAX engine cut-out relay (if equipped) employed to disable the engine from starting
10. HST controller power holding relay when the KOMTRAX terminal receives an
11. Starting motor safety relay engine cut command issued through external
12. Starting motor operation.
13. Alternator (if equipped)
14. HST controller
15. Engine controller
16. Machine monitor
17. KOMTRAX terminal (if equipped)
18. Engine controller cut-out relay
19. CAN resistor
22 WA200-6
Operation
1. When starting switch is turned "ON"
q As the starting switch is turned "ON", ter-
minals B and BR of the starting switch are
closed and the current flows from the bat-
tery through the starting switch and bat-
tery relay coil to the ground, thereby
closing the contact of the battery relay. As
a result, the power is supplied to each cir-
cuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.
2. Neutral safety circuit

q Setting the directional lever to "N (neu-
tral)" conducts the current from contact N
of the directional lever to the neutral safety
relay to activate it.
3. When starting switch is set to "START"

q As the starting switch is set to "START",
the current flows through the starting
switch terminal C, KOMTRAX engine cut-
out relay and neutral safety relay to the
starting motor safety relay to start the
engine.
q When the directional lever is set to any
position other than "N (neutral)", the neu-
tral safety relay is not activated and inter-
rupts the engine startup.
q As KOMTRAX terminal receives the exter-
nally applied engine cut-out command,
KOMTRAX engine cut-out relay is acti-
vated, shutting down the circuit from the
starting switch terminal C to the starting
motor safety relay. Thus, engine start-up
becomes unavailable.
(if equipped)
WA200-6 23
Engine stopping circuit 1
Operation
q Setting the starting switch to "OFF" cuts off
ACC signal from the starting switch terminal
ACC to the engine controller.
q Although ACC is cut off, the engine controller
keeps the engine controller cut-out relay work-
ing to maintain the current flow to the engine
controller until its internal processing is com-
plete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation, stopping supply
of the voltage from the alternator terminal L.
And the current from the starting switch termi-
nal BR is also stopped and the contacts of the
battery relay are opened. Consequently, the
power supplied to each circuit of the machine
is stopped.
24 WA200-6
Preheating circuit 1
1. Battery Operation
2. Battery relay q Set the starting switch to "ON" to start the
3. Slow-blow fuse engine controller. At this time, if intake air tem-
4. Fuse box 1 perature is -4°C or below, the engine controller
5. Starting switch starts up the electrical intake air heater imme-
6. Engine controller diately after the starting switch is turned "ON"
7. Machine monitor to initiate preheating by the electrical intake air
8. Electrical intake air heater relay heater.
9. Electrical intake air heater q The preheating time is set as shown below.
10. Boost pressure and temperature sensor
Outline
q The automatic preheating system is installed
so that the engine will start easily in a cold dis-
trict.
q The automatic preheating system is capable of
cutting the preheating time short as the starting
switch is set to "ON". This system is also capa-
ble of automatically setting the preheating
duration referencing temperature of intake air.
q Setting the starting switch to "ON" lights the
preheater pilot lamp of the machine monitor
and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating dura-
tion referencing the intake air temperature
being sent from the boost pressure sensor and
temperature sensor.
q The pilot lamp remains turned on as long as
preheating is continued. Keep the starting
switch in the "ON" position during this time.
Setting the starting switch to "START" from this
state resets preheating.
WA200-6 25
Engine output derating function 1 Automatic warm-up function 1
q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque function warms it up by increasing the engine
or speed. low idle speed.
q If the coolant temperature is below 20°C at
q Following figure shows the engine torque per- starting of the engine, this function increases
formance when the torque was derated. the low idle speed to 1,000 rpm, and to 900
rpm in the range from 20°C to 40°C. The con-
ditions required for increasing the low idle
speed depend on the coolant temperature as
shown in the figure below.
q If the coolant temperature reaches 30°C or
above, the low idle speed decreases to 900
rpm. If it reaches 50°C or above, it returns to
825 rpm.
A: Derated to approximately 30% of the maximum

torque point
B: Derated to approximately 50% of the rated out-
put point
q Following figure shows the engine torque per-

formance when the engine speed was derated.
The automatic warm-up function is reset and the

engine speed returns to 825 rpm as any of the fol-
lowing conditions is met.
The coolant temperature reaches 50°C or
Condition 1 above while the automatic warm-up
function is enabled.
The accelerator pedal angle remains at
Condition 2
100% for 30 seconds or more.
The automatic warm-up function remains
Condition 3
being enabled for 50 minutes or more.
The directional lever or directional
selector switch is set to "Forward" or
"Reverse" while the automatic warm-up
function is enabled.
A: Derated near to the engine speed at maximum Condition 4
(When the directional lever and
torque point directional selector switch are returned to
"Neutral" to stop the machine, the
automatic warm-up function restarts.)
26 WA200-6
WA200-6 27
Parking brake circuit 1
1. Parking brake lever intermediate switch

2. Parking brake lever bottom switch
3. HST controller
4. Machine monitor
5. Alarm buzzer
6. HST controller power holding relay
7. HST safety relay
8. Clutch solenoid valve
9. HST motor 1 solenoid valve
10. HST pump forward solenoid valve
11. HST pump reverse solenoid valve
28 WA200-6
Operation
Starting switch position OFF ON
State of engine Stopped Running
Parking brake lever area Free Mid Lock Free Mid Lock Free Mid Lock
Parking brake lever Close Open Close Open Close Open
intermediate switch (1)
Parking brake lever
bottom switch (2) Close Open Close Open Close Open
[for parking brake pilot
lamp operation]
Parking brake reminder [*1], [*2] OFF [*1] OFF OFF
caution lamp ON (Reset) ON (Reset) (Reset)
(Alarm buzzer) (Sounded) (Sounded)
Parking brake pilot lamp OFF OFF ON OFF ON
When the parking brake lever is set to "Mid"

position
q When the parking brake lever is set to the mid
position, the bottom switch (2) is open but
intermediate switch (1) is closed.
q The parking brake pilot lamp comes on only
when the starting switch is "ON".
q As bottom switch (2) opens, the output to the
forward and reverse solenoid valves of HST
pump is stopped to prevent dragging of the
parking brake. And, at the same time, the
directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
When the parking brake lever is set to "Free" *1: When the starting switch is turned from "ON" to
position "OFF":
q When the parking brake lever is set to the free q The parking brake reminder caution lamp turns
position, the intermediate switch (1) and bot- on and the alarm buzzer sounds.
tom switch (2) are both closed. q The HST controller power holding relay
q The parking brake pilot lamp goes off indepen- remains turned on, conducting current to the
dent of the given state. HST controller and maintaining the HST motor
q The parking brake is released. 1 solenoid valve and clutch solenoid valve
*1: When the starting switch is turned from "ON" to being activated. Thus, the machine is pro-
"OFF": tected from slipping through a slope.
q The parking brake reminder caution lamp turns
on and the alarm buzzer sounds. When the parking brake lever is set to "Lock"
q The HST controller power holding relay position
remains turned on, conducting current to the q Pulling the parking brake lever fully opens both
HST controller and maintaining the HST motor the intermediate switch (1) and bottom switch
1 solenoid valve and clutch solenoid valve (2).
being activated. Thus, the machine is pro- q The parking brake pilot lamp comes on only
tected from slipping through a slope. when the starting switch is "ON".
*2: If the parking brake lever is set to any position q The parking brake reminder caution lamp goes
other than "Lock" when the starting switch is at off independent of the given state.
"OFF", the parking brake reminder caution q As bottom switch (2) opens, the output to the
lamp remains turned off and the alarm buzzer forward and reverse solenoid valves of HST
is also not activated. And HST motor 1 sole- pump is stopped to prevent dragging of the
noid valve and clutch solenoid valve remain parking brake. And, at the same time, the
inactivated. directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
q The parking brake is activated.
WA200-6 29
Max. traction switch 1
1. Switch A Function
Mono-lever type : green wiring harness q These switches are installed on the knob of the
2-lever type : white wiring harness work equipment (lift arm) control lever. Switch
2. Switch B A (1) functions as the max. traction switch and
Mono-lever type : white wiring harness switch B (2) functions as an optional switch
2-lever type : yellow wiring harness [reserved].
3. Wiring harness q Both of switch A (1) and switch B (2) are of
momentary type, that is, their contacts are
closed only while they are pressed.
30 WA200-6
Sensor 1
Speed sensor
1. Hall IC 5. Heat shrink tube

2. Circuit board 6. Protective tube
3. O-ring 7. Lead wire
4. Housing 8. Connector
Function
q The speed sensor is installed on the transfer case. It generates two different types of pulses depending
on the rotational direction and speed of the gear.
WA200-6 31
HST oil temperature sensor

Brake oil temperature sensor
1. Connector 2. Plug 3. Thermistor
Function
q The HST oil temperature sensor and the brake oil temperature sensor are installed on the motor 2
hydraulic piping and front axle, respectively. They generate the signal for the change in temperature as
variation in the resistance of the thermistor.
HST oil pressure sensor
1. Sensor 2. Lead wire 3. Connector
Function
q The HST oil pressure sensor is installed on the motor 2 solenoid block to measure the oil pressure in the
HST circuit and generate the corresponding signal.
32 WA200-6
HST oil filter clogging sensor
1. Terminal 2. Plug
Function
q This sensor is installed on the HST oil filter to monitor the oil pressure before and after the filter. If the
pressure goes beyond the specified level, the switch is set to "ON".
Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
q This sensor is installed in the bulkhead. As the coolant goes below the specified level, the float moves
down, and the switch is set to "OFF".
WA200-6 33
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
34 WA200-6
Accelerator pedal sensor
1. Pedal Output characteristics

2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pedal pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.
Idle validation signal

q The sensor detects the accelerator pedal oper-
ation. As the accelerator pedal is released, it
outputs the signal being entered to No. 5 pin
from No. 4 pin. And as the accelerator pedal is
pressed, it outputs the signal being entered to
No. 6 pin from No. 4 pin.
WA200-6 35
Water-in-fuel sensor
1. Connector 3. Sensor
2. Tube 4. O-ring
Function
q This sensor is installed in the cup of the fuel pre-filter. It outputs the signal as entrainment of water in fuel
is sensed.
Boom kick-out proximity switch

(if equipped)
Bucket positioner proximity switch
1. Switch 3. Operation indication lamp

2. Locknut 4. Connector
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame.
And the bucket positioner proximity switch is installed on the bucket cylinder. As long as the plate is
positioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".
36 WA200-6
WA200-6 37
SEN03259-00

©2007 KOMATSU
All Rights Reserved
38
SEN03731-00
WA200-6
WA200-6 70001 and up
20 Standard value table 1

Standard service value table
Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
WA200-6 1
SEN03731-00 20 Standard value table
Standard service value table 1

Standard service value table for engine 1
Machine model WA200-6

Engine SAA4D107E-1
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle (*) 2,225 (+70/-50) 2,225 (+70/-50)
Engine speed rpm
Low idle (*) 825 (+25/-50) 825 (+25/-50)
Exhaust temperature
All revolution ranges
(Turbocharger outlet tem- °C Max. 700 750
(Atmospheric temperature: 20°C)
perature)
Intake air pressure • At rated output kPa Min. 133 107
(Boost pressure) • At aftercooler outlet side {mmHg} {Min. 1,000} {800}
Engine coolant tempera- At rated output Pollution Max. 12 22

Exhaust gas color
ture: Within operating range At sudden acceleration level % Max. 25 35
Intake valve 0.25 ± 0.05 0.152 – 0.382
Valve clearance Normal temperature mm
Exhaust valve 0.51 ± 0.05 0.381 – 0.763
• At rated output
kPa Max. 0.98 1.96
Blow-by pressure • Engine coolant temperature: Within operating
{mmH2O} {Max. 100} {200}
range
At high idle
SAE0W30E0S Min. 0.29 0.25
Engine coolant tempera-
{Min. 3.0} {2.5}
ture: Within operating range SAE0W40E0S MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.10 0.07
Engine coolant tempera- SAE30DH {Min. 1.0} {0.7}
ture: Within operating range
Oil temperature All engine speed ranges (Inside oil pan) °C 80 – 110 Min. 120
Deflection under finger pres-
Idler pulley –
sure of approx. 58.8 N Auto-tensioner Auto-tensioner
crankshaft pulley
{approx. 6 kg}
Belt tension mm
Deflection under finger Air conditioner com-
pressure of approx. 98 N pressor – crankshaft 8 – 11 8 – 11
{approx. 10 kg} pulley
*: Value when mounted on machine (Different from value in Engine Shop Manual)
2 WA200-6
Standard service value table for chassis 1

Category
Standard value Service limit

Item Measurement conditions Unit
for new machine value
5.9 (+5.9/0)
N–
13.7 {1.4}
FORWARD {0.6 (+0.6/0)}
Operating N
Directional lever
effort {kg}
5.9 (+5.9/0)
N– • Engine stopped 13.7 {1.4}
REVERSE {0.6 (+0.6/0)}
• Measure at 10 mm from top of lever
N– 45 ± 10 45 ± 20
FORWARD
Travel mm
N–
45 ± 10 45 ± 20
REVERSE
7.8 ± 4.9 15.7
1st – 2nd
Speed switch (Dial switch)
{0.8 ± 0.5} {1.6}

Operating • Engine stopped N 7.8 ± 4.9 15.7
2nd – 3rd
effort • Measure at 10 mm from end of switch knob {kg} {0.8 ± 0.5} {1.6}
7.8 ± 4.9 15.7
3rd – 4th {0.8 ± 0.5} {1.6}
1st – 2nd 30 ± 5 30 ± 10
Travel 2nd – 3rd • Engine stopped deg. 30 ± 5 30 ± 10
3rd – 4th 30 ± 5 30 ± 10
14.7 (+4.9/0)
HOLD o RAISE 29.4
{1.5 (+0.5/0)} {3}
18.6 (+4.9/0)
35.3
RAISE o HOLD
{1.9 (+0.5/0)} {3.6}
12.3 (+4.9/0)
25.7
HOLD o LOWER
Lift arm {1.25 (+0.5/0)} {2.6}
Work equipment control lever
LOWER o HOLD — —
• Engine coolant tempera-
ture: Operating range 18.6 (+4.9/0)
35.3
LOWER o FLOAT {3.6}
Operating • Engine speed: Low idle N {1.9 (+0.5/0)}
effort • Hydraulic oil tempera- {kg}
ture: 21.6 (+4.9/0)
FLOAT o HOLD 39.7
60 – 80°C {4.0}
{2.2 (+0.5/0)}
16.7 (+4.9/0)
32.3
HOLD o DUMP
{1.7 (+0.5/0)} {3.3}
14.7 (+4.9/0)
Bucket HOLD o TILT 29.4
{1.5 (+0.5/0)} {3}
18.6 (+4.9/0)
27.9
TILT o HOLD
{1.9 (+0.5/0)} {2.9}
HOLD o RAISE
Work equipment control lever
46 ± 9 46 ± 12
Lift arm HOLD o LOWER 46 ± 9 46 ± 12
• Engine coolant tempera-
LOWER o FLOAT 14 ± 9 14 ± 12
ture: Operating range
• Engine speed: Low idle HOLD o DUMP 60 ± 9 60 ± 12
Travel mm
• Hydraulic oil tempera-
ture:
Bucket 60 – 80°C HOLD o TILT 46 ± 9 46 ± 12
WA200-6 3

Category

• Engine stopped
Play mm Max. 50 Max. 100
• Machine facing straight to front
• Flat, level, straight, dry, and paved road 9.8 ± 2.9 Max.14.7
Operating effort N {kg}
Steering wheel
• Engine speed: Low idle (Bucket empty) {1.0 ± 0.3} {Max. 1.5}
• Engine speed: High idle
Turns (Not including play) Turns 4.1 ± 0.4 4.1 ± 0.8
• Left lock – right lock
Low idle • Engine started 3.7 ± 0.4 Max. 4.8

Operating • Hydraulic oil temperature: Within operating
sec.
time range
High idle • Left lock – right lock 3.7 ± 0.3 3.7 ± 1
Beginning of 24.5 – 37.8

—
Operating depression • Engine started {2.5 – 3.9}
Accelerator pedal
N {kg}
effort • Measure at 150 mm from fulcrum of pedal. 45.5 – 58.8
Full open —
{4.6 – 6.0}
Neutral (α1) a For measuring posture, see Fig. A at end of 45 ± 2 —

Operating this section
deg.
angle • Engine started
Stroke (α) • α = α1 - α2 17 ± 2 —
• Operating angle: 20°

• Engine speed: Low idle 294 ± 30 Min. 238
Operating effort N {kg}
• Hydraulic oil temperature: Within operating {30 ± 3.0} {Min. 24.3}
range
Brake pedal
Neutral (α1) a For measuring posture, see Fig. B at end of 50 —

Operating
angle this section
Max. (α2) • Engine speed: Low idle deg. 20 (+2/0) —
• Hydraulic oil temperature: Within operating
range
Play 5±1 —
HST stall 2,180 ± 100 2,180 (+115/–200)

Engine speed
• Engine coolant temperature: Within operating

range
Hydraulic stall rpm 2,070 ± 100 2,070 ± 200
• HST oil temperature: 60 – 80°C
• Hydraulic oil temperature: 45 – 55°C
HST stall + hydraulic stall 2,060 (+110/–200) 2,060 (+210/–300)
1st 4 ± 0.2 4 ± 0.3

Power train (HST)
2nd 13 ± 0.7 13 ± 0.9

Travel speed
FORWARD km/h
(Bucket empty)
3rd 20 ± 1.0 20 ± 1.4
4th 34.5 ± 1.7 34.5 ± 2.4
4 WA200-6

Category

1st 4 ± 0.2 4 ± 0.3
2nd 13 ± 0.7 13 ± 0.9

Travel speed
REVERSE km/h
(Bucket empty)
3rd 20 ± 1.0 18 ± 1.3
4th 34.5 ± 1.7 34.5 ± 2.4
• Engine speed: Full speed

• Hydraulic oil temperature: 45 – 55°C 45.6 (+1.0/-2.5)
High pressure 45.6 ± 1.0
• Directional lever: FORWARD
cut-off pressure {465 ± 10} {465 (+10/-25)}
• Speed switch: 2nd speed
• Traction control switch: ON
Low pressure
• Engine speed: Full speed
relief pressure 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
• Hydraulic oil temperature:
Power train (HST)
(Work equip-
45 – 55°C {25.5 (+2/0)} {25.5 (+2/-1)}
ment PPC cir-
• Directional lever: N
cuit pressure)
• Engine speed: 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
HST oil Full speed When brake pedal releasing
pressure Servo piston • Hydraulic oil {25.5 (+2/0)} {25.5 (+2/-1)}
control oil pres- temperature:
sure 45 – 55°C
When brake pedal depress- Max. 0.6 Max. 0.6
• Directional ing MPa {Max. 6} {Max. 6}
lever: N {kg/
cm2}
• Hydraulic oil temperature: 45 – 55°C
• Gear speed selector switch: 1st
Servo piston • Travel speed control dial: “1” on Min. side 2.5 (+0.2/0)
operating pres- • Directional lever: Measure in both forward 2.5 ± 0.2
{25.5 (+2/0)} {25.5 ± 2}
sure and reverse position.
• Measure while driving at full throttle (Max.
speed: 5 km/h).
45 – 55°C 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
Clutch control
Transfer • Directional lever: FORWARD
pressure {25.5 (+2/0)} {25.5 (+2/-1)}
• Speed switch: 3rd or 4th speed
• Travel at a speed of at least 10 km/h
Steering
20.6 ± 0.7 20.6 ± 2.0

Steering relief pressure • Hydraulic oil temperature:
{210 ± 7} {210 ± 20}
45 – 55°C
• Tire size:
• Flat, horizontal, straight, 17.5 – 20
dry paved road surface • Speed when
• Braking delay: Within 0.1 m Max. 5 Max. 5
applying
sec brake:
Wheel brake
• Brake pedal operating 20 km/h

Performance effort:
322 N {33 kg} • Tire size:
• Tire inflation pressure: 20.5 – 25
Specified pressure • Speed when
m Max. 12 Max. 12
• Measure braking dis- applying
tance brake:
35 km/h
Disc wear • Thickness of lining mm 1 ± 0.1 Max. 0.6
• Tire inflation pressure: Specified pressure
Parking brake
• Flat paved road with 1/5 (11°20') grade

Performance • Machine at operating condition — Holds position Holds position
a For measuring posture, see Fig. C and Fig. D
at the end of this section
WA200-6 5

Work equipment control valve Category

• Engine speed: High idle MPa 20.6 ± 0.4 20.6 ± 2.0

Relief pressure • Hydraulic oil temperature: {kg/ {210 ± 4} {210 ± 20}
45 – 55°C cm2}
• Engine speed: High idle RAISE 5.5 ± 0.5 Max. 8.2

Lift arm • Hydraulic oil tempera- *1
LOWER 3.6 ± 0.5 Max. 4.7
ture:
45 – 55°C TILT 2.3 ± 0.3 Max. 3.8
Speed • Steering valve: Neutral *2 Sec.
• Apply no load DUMP 1.4 ± 0.3 Max. 2.5
Bucket
a For measuring posture,
Work equipment
see Fig. E – Fig. H at the TILT *3 1.4 ± 0.3 Max. 2

end of this section
•
Bucket no load
•
Position of work equipment: Lift arm and
Lift arm cylin-
der bucket in level position Max. 20 Max. 30
• Engine stopped
Hydraulic drift mm
45 – 55°C
• Stop engine and leave for 5 minutes, then
Bucket cylinder measure for 15 minutes. Max. 17 Max. 20
a For measuring posture, see Fig. J at the end of
this section
Hydraulic drive fan
• Engine coolant temperature: Min. 90°C

Max. fan speed rpm 1,750 ± 50 1,750 ± 100
• Boost temperature: Min. 70°C
• HST oil temperature: Min. 95°C
MPa
• Engine coolant temperature: Min. 90°C 14.7 ± 1.5 14.7 ± 2.3
Fan drive pressure {kg/
• Boost temperature: Min. 70°C {150 ± 15} {150 ± 23}
cm2}
• HST oil temperature: Min. 95°C
Proximity switch
Clearance between bucket

3–5 —
positioner switch
mm
45 – 55°C
Clearance between boom kick-
3–5 —
out switch
*1: Time taken to raise bucket from contact with ground (bottom of bucket horizontal) to max. height of lift
arm.
*2: Time taken to move bucket from max. tilt to max. dump.
*3: Time taken to move bucket from horizontal position to max. tilt.
6 WA200-6
Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
WA200-6 7
a Fig. G
a Fig. H
a Fig. J
8 WA200-6
WA200-6 9
SEN03731-00

© 2007 KOMATSU
All Rights Reserved
10
SEN03732-00
WA200-6
WA200-6 70001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 8
Measuring exhaust gas color ........................................................................................................................ 10
Adjusting valve clearance ............................................................................................................................. 12
Measuring compression pressure................................................................................................................. 14
Measuring blow-by pressure......................................................................................................................... 17
Testing engine oil pressure ........................................................................................................................... 18
Measuring intake air (boost) pressure .......................................................................................................... 19
Handling fuel system equipment................................................................................................................... 21
Releasing residual pressure in fuel system .................................................................................................. 21
Measuring fuel pressure ............................................................................................................................... 22
Measuring fuel return rate and leakage ........................................................................................................ 24
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing leakage in fuel system ...................................................................................................................... 29
Handling reduced cylinder mode operation .................................................................................................. 30
Handling no-injection cranking operation...................................................................................................... 30
WA200-6 1
SEN03732-00 30 Testing and adjusting
Handling controller voltage circuit ................................................................................................................. 31

Check of muffler and muffler stack for looseness and damage .................................................................... 31
Check of muffler function .............................................................................................................................. 32
Check of installed condition of cylinder head and manifolds......................................................................... 32
Check of engine piping for damage and looseness ...................................................................................... 33
Testing and adjusting air conditioner compressor belt tension...................................................................... 33
Replacing alternator belt ............................................................................................................................... 34
2 WA200-6
Tools for testing, adjusting, and troubleshooting 1
Testing and Sym- Q'ty

Part No. Part Name Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve
B Commercially
clearance 2 Clearance gauge 1
available
1 795-799-6700 Puller 1 For 107E-1 engine
Measuring compression 2 795-502-1590 Gauge assembly 1 0 – 7 MPa {0 – 70 kg/cm2}
C
pressure 3 795-790-4410 Adapter 1 For 107E-1 engine
4 6754-11-3130 Gasket 1 For 107E-1 engine
Measuring blow-by
D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester
Measuring engine oil 1 1 {25, 60, 400, 600 kg/cm2}
E
pressure 790-261-1204 Digital hydraulic tester Pressure gauge: 60 MPa {600 kg/cm2}
2 799-101-5160 Nipple 1
Measuring intake air
F 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Measuring fuel 6732-81-3170 Adapter 1 10 × 1.0 mm o R1/8

G 2
compression pressure 6215-81-9710 O-ring 1
3 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
2 795-790-6700 Adapter 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Measuring fuel return Commercially
H 4 Measuring cylinder 1
rate and leakage available
Commercially
5 Stopwatch 1
available
Commercially Hose
6 1
available (Inside diameter: 14 mm)
Testing accelerator
J 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
pedal
1 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing directional lever K Commercially
2 Scale 1
available
Testing and adjusting 799-101-5002 Analog hydraulic tester 1
L {25, 60, 400, 600 kg/cm2}
HST oil pressure
WA200-6 3
Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
799-101-5002 Analog hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing clutch control 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
M
pressure
799-401-3100 Adapter 1
2 For hose size #02
02896-11008 O-ring 1
Testing steering wheel N 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing and adjusting 799-101-5002 Analog hydraulic tester 1
P {25, 60, 400, 600 kg/cm2}
steering oil pressure
1 799-205-1100 Tachometer kit 1 Digital display: 6 – 99999.9 rpm
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic fan Q
799-401-3300 Adapter 1
3 For hose size #04
02896-11012 O-ring 1
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
accumulator charge R {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Testing wheel brake oil
S 4 790-301-1720 Adapter 1 20 × 1.5 mm o R1/8
pressure
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Holding work equip-
T 793-463-1100 Stopper 1
ment position
Testing wear of brake
U 418-98-31110 Testing gauge 1 Component part of tool kit
disc
Testing and adjusting
parking brake control V 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
cable
1 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing work equip-
W Commercially
ment lever 2 Scale 1
available
work equipment oil X {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

work equipment PPC Y {25, 60, 400, 600 kg/cm2}
oil pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
4 WA200-6
Testing and Sym-

adjusting item bol
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 REL-5P (5 pins)
799-601-7310 T-adapter 1 SWP (12 poles)
799-601-7070 T-adapter 1 SWP (16 poles)
799-601-4101 T-adapter assembly 1 Connected with engine
Diagnosis for engine
related controller, sen- 799-799-5530 • T-adapter 1 Engine coolant temperature
Z
sor actuator and har- 799-601-4230 • T-adapter 1 Boost temperature/pressure sensor
ness
799-601-4130 • T-adapter 1 Ne sensor, CAM sensor
799-601-4160 • T-adapter 1 Hydraulic pressure sensor
799-601-4211 • T-adapter 1 Controller (50 poles)
799-601-4140 • T-adapter 1 Atmospheric pressure sensor
799-601-4340 • T-adapter 1 Pump actuator
799-601-4190 • T-adapter 1 Common rail pressure sensor
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter 1 799-601-2900 is not supplied
or
799-601-7100
or
799-601-4700
or
799-601-8000
799-601-2600 • T-adapter box 1 Econo (Excl. 799-601-2700)
799-601-2740 • Adapter for MIC 1 For MIC-5P
Diagnosis for chassis 799-601-4101 T-adapter assembly 1
related controller, sen-
Z 799-601-4211 • Adapter for DRC 1 For DRC50
sor actuator and har-
ness 799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
799-601-7010 • Adapter for X 1 For X1P
799-601-7050 • Adapter for SWP 1 For SWP6P
WA200-6 5
Testing and Sym-

adjusting item bol
799-601-7060 • Adapter for SWP 1 For SWP8P (Excl. 799-601-8000)
For M1P (Excl. 799-601-7000 and
799-601-7080 • Adapter for M 1
799-601-7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7150 • Adapter for S 1 For S10P
799-601-7180 • Adapter for AMP040 1 For A8P (799-601-7400 only)
For A12P (Excl. 799-601-7000 and
799-601-7190 • Adapter for AMP040 1
799-601-7100)
799-601-7330 • Adapter for S 1 For S16PW (799-601-8000 only)
799-601-7320 Adapter for SWP 1 For SW16P
799-601-7340 Adapter for M 1 For M8P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7370 Adapter for relay 1 For REL-6P
799-601-7500 T-adapter assembly 1
799-601-7520 • Adapter for 070 1 For 070-12P
799-601-7530 • Adapter for 070 1 For 070-14P
Diagnosis for chassis 799-601-7540 • Adapter for 070 1 For 070-18P
related controller, sen- 799-601-7550 • Adapter for 070 1 For 070-20P
Z
sor actuator and har-
ness 799-601-9000
or T-adapter assembly 1
799-601-9200
For DT2P (Incl. in 799-601-9020
799-601-9020 • Adapter for DT 1
and 799-601-7000)
For DT4P (Incl. in 799-601-9020
799-601-9040 • Adapter for DT 1
and 799-601-7000)
799-601-9060 • Adapter for DT (Gray) 1 For DT8PGR
799-601-9070 • Adapter for DT (Black) 1 For DT8PB
799-601-9080 • Adapter for DT (Green) 1 For DT8PG
799-601-9110 • Adapter for DT (Gray) 1 For DT12PGR
799-601-9120 • Adapter for DT (Black) 1 For DT12PB
799-601-9130 • Adapter for DT (Green) 1 For DT12PG
799-601-9140 • Adapter for DT (Brown) 1 For DT12P
799-601-9300 T-adapter assembly 1
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
• Multi-adapter for
799-601-9890 1 For DT2–4, DTM2
DT2–4, DTM2
Measuring coolant and
— 799-101-1502 Digital thermometer 1
oil temperature
Measuring time and Commercially
— Stopwatch 1
speed available
6 WA200-6
Testing and Sym-

adjusting item bol
Measuring voltage and Commercially
— Tester 1
resistance available
Removal and installation
Commercially 3.26 mm TORX wrench
of boost pressure and — TORX wrench 1
available (KTC Q4T15 or equivalent)
temperature sensor
Removal and installation
Commercially 21 mm deep socket
of engine coolant — Deep socket 1
available (MITOLOY 4ML-21 or equivalent)
temperature sensor
WA200-6 7
Measuring engine speed 1 2. Measuring HST stall speed

1) Referring to “Special function of machine
k Put chocks under the tires securely. monitor”, select the real time monitoring
k When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01001: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.04408: HST OIL TEMP
Within operating range (HST oil temperature)
q HST oil temperature:
Within operating range
1. Measuring engine speed (low idle and high

idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Display “ENG SPEED” from the monitor-
ing items of the machine monitor.
a Monitoring item
Code No. 01001: ENG SPEED
(Engine speed)
3) Start the engine.

4) Lower the bucket to near the ground, then
drive the machine forward and thrust the
bucket into the stockpile of soil or rock
(portion a).
3) Start the engine, set it in the measuring

condition, and measure the engine speed.
5) While running the engine at high idle,

press the accelerator pedal gradually.
When the HST stalls, measure the engine
speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the HST for more
than 20 seconds. Take care that the
HST oil temperature will not exceed
120°C.
8 WA200-6
3. Measuring hydraulic stall speed 4. Measuring HST stall and hydraulic stall (full
1) Referring to “Special function of machine stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing HST stall speed”.
2) Display “ENG SPEED” from the monitor- 2) Start the engine.
ing items of the machine monitor. 3) Lower the bucket to near the ground, then
a Monitoring item drive the machine forward and thrust the
Code No. 01001: ENG SPEED bucket into the stockpile of soil or rock
(Engine speed) (portion a).
3) Run the engine at high idle. 4) While running the engine at high idle, stall
4) Relieve the lift arm cylinder or bucket cyl- the HST and relieve the lift arm cylinder or
inder on the extraction side and measure bucket cylinder on the extraction side
the engine speed. simultaneously and measure the engine
a Finish measurement in a short time speed at this time.
so that the hydraulic oil temperature a Do not keep stalling the HST for more
will not exceed 120°C. than 20 seconds. Take care that the
120°C.
WA200-6 9
Measuring exhaust gas color 1 2. Measuring with smoke meter A2

1) Insert the probe of smoke meter A2 in the
a Necessary tools outlet of the muffler (exhaust pipe) and fix
Symbol Part No. Part Name it to the exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k When installing and removing the measuring

instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the fol-
lowing condition.
q Engine coolant temperature: Within oper-
ating range
2) Connect the probe hose, receptacle of the
1. Measuring with handy smoke checker A1 accelerator switch, and air hose to smoke
1) Stick a sheet of filter paper to smoke meter A2.
checker A1. a Keep the pressure of the supplied
2) Insert the exhaust gas intake pipe in the compressed air at 1.5 MPa {15 kg/
muffler (exhaust pipe). cm2} or below.
3) Start the engine and heighten the engine 3) Connect the power cable to a 100 V AC
coolant temperature to the operating range. receptacle.
4) Accelerate the engine suddenly and run it a Confirm that the smoke meter power
at HST stalling and hydraulic stalling, and switch is in the OFF position, before con-
operate the handle of smoke checker A1 necting the power cable to an outlet.
so that the filter paper will absorb the 4) Loosen the cap nut of the suction pump
exhaust gas. and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter A2.
5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
10 WA200-6
6) Start the engine and keep it running until

the engine coolant temperature rises to
the operating range.
7) Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter A2 and collect the
exhaust gas into the filter paper.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets)
in the filtering paper holder, and read the
indicated value.
9) After finishing work, remove the used
instruments and return the removed parts.
WA200-6 11
Adjusting valve clearance 1 5. Remove plate (4) and plug (5) under the start-
ing motor and insert gear B1.
a Necessary tools
Symbol Part No. Part Name
1 795-799-1131 Gear
B Commercially
2 Clearance gauge
available
a Adjust the valve clearance under the following

condition.
q Engine coolant temperature: Normal tem-
perature
1. Open the engine right and left side covers.
2. Remove blow-by duct (2) and bracket (3) of

cylinder head cover (1). 6. Rotate the crankshaft forward (clockwise, see-
ing from the fan) with gear B1 and set wide slit
3. Remove cylinder head cover (1). (b) of the rotation sensor ring to projection top
a The engine hood does not need to be (a) of front cover.
removed. a Projection top (a) must be within the range
of wide slit (b) when it is seen from the air
conditioner compressor side.
a After the above positioning, the No. 1 cyl-
inder or No. 4 cylinder is not at the top
dead center (TDC). Take care. (The cylin-
der is at 76 – 88° before the top dead cen-
ter.)
4. Remove 2 bolts (7) of relay (6) under the start-

ing motor and move the relay.
7. Check the movement of the rocker arm of the

No . 1 c yl i nd er to j u dg e th e va l ve to b e
adjusted.
a If you can move the rocker arms of air

intake valves (IN) with the hand by the
valve clearance, adjust the valves marked
with Q in the valve arrangement drawing.
a If you can move the rocker arms of
exhaust valves (EX) with the hand by the
valve clearance, adjust the valves marked
with q in the valve arrangement drawing.
a Valve arrangement drawing
12 WA200-6
a If the valves marked with Q in the valve

arrangement drawing were adjusted in
steps 7 and 8, adjust the valves marked
with q.
11. After finishing adjustment, remove the adjust-

ing tools and return the removed parts.
a Remove gear B1 without fail.
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
8. Adjust the valve clearance according to the fol-

lowing procedure.
1) While fixing adjustment screw (10), loosen
locknut (11).
2) Insert clearance gauge B2 in the
clearance between rocker arm (12) and
crosshead (13) and adjust the valve
clearance with adjustment screw (10).
a With the clearance gauge inserted,
turn the adjustment screw to a degree
that you can move the clearance
gauge lightly.
3) While fixing adjustment screw (10), tighten
locknut (11).
3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
9. Rotate the crankshaft forward by 1 turn and set

wide slit (b) to projection top (a) according to
step 6.
10. Adjust the other valve clearances according to

steps 7 and 8.
a If the valves marked with q in the valve
arrangement drawing were adjusted in
steps 7 and 8, adjust the valves marked
with Q.
WA200-6 13
Measuring compression 4. Loosen injector terminal nut (4) and remove

pressure 1 the terminal from the injector.
a Necessary tools 5. Set the cylinder to be checked to the compres-

Symbol Part No. Part Name sion top dead center.
a How to turn the crankshaft, refer to
1 795-799-6700 Puller
“Adjusting valve clearance”.
2 795-502-1590 Gauge assembly a When the cylinder is at the compression
C
3 795-790-4410 Adapter top dead center, the rocker arm of the cyl-
4 6754-11-3130 Gasket inder can be moved by the valve clear-
ance with the hand.
k When measuring the compression pres-
sure, take care not to burn yourself on the 6. Remove rocker arm assembly (5).
exhaust manifold or muffler or get caught
in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C)
1. Remove cylinder head cover (1). For details,

see Disassembly and assembly, “Removal and
installation of cylinder head assembly”.
2. Disconnect 2 injector wiring harness connec-

tors (2) and move the wiring harnesses.
7. Remove retainer (6) and fuel inlet connector (7).
8. Remove holder (8).
9. Remove injector (9).

a Using puller C1, remove the injector with
impacts of a slide hammer.
a Do not remove the injector by prying its
top up.
3. Disconnect fuel high-pressure tube (3).
14 WA200-6
16. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the gauge when its pointer is stabi-
lized.
17. After finishing measurement, remove the mea-

suring tools and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) While matching projection (a) of the injec-
tor to notch (b) of the holder, set the injec-
tor to the cylinder head.
a When setting the injector, direct the
above matching position toward the
10. Fit gasket C4 to the end of adapter C3 and fuel inlet connector insertion side.
insert them in the injector mounting portion.
11. Fix adapter C3 with injector holder.

a Tighten the holder mounting bolts alter-
nately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
12. Connect gauge assembly C2 to adapter C3.

a If engine oil is applied thinly to the con-
necting parts of the adapter and gauge, air
does not leak easily.
13. Install rocker arm assembly (5).

3 Rocker arm assembly mounting bolt: 2) Tighten injector holder mounting bolts (10)
36 ± 5 Nm {3.67 ± 0.51 kgm} by 3 – 4 turns.
3) Set fuel inlet connector (7).
14. Adjust the valve clearance. a Push in the fuel inlet connector until
a See “Adjusting valve clearance”. the O-ring is fitted and the connector
clicks.
4) Temporarily tighten retainer (6) of fuel inlet
connector (7).
a Tighten the above retainer in step 6).
3 Retainer:
15 ± 5 Nm {1.5 ± 0.5 kgm}
5) Tighten injector holder mounting bolts (10)
alternately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}
15. Referring to “Special functions of machine moni-

tor (EMMS)”, set the engine in the no-injection
cranking mode.
k If the engine is not set in the no-injec-
tion cranking mode, it starts during
measurement and that is dangerous.
Accordingly, be sure to set the engine
in the no-injection cranking mode.
WA200-6 15
6) Permanently tighten retainer (6) of fuel

inlet connector (7).
3 Retainer:
50 ± 5 Nm {5.1 ± 0.51 kgm}
7) Tighten the sleeve nut of the fuel high-

pressure tube on the head side and then
tighten that on the common rail side.
3 Sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
8) Connect the injector harness connector.
aAfter installing the rocker arm assembly, adjust

the valve clearance. For details, see “Adjusting
valve clearance”.
3 Rocker arm assembly mounting bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
aTighten the injector terminal nut to the follow-

ing torque.
3 Terminal nut:
1.5 ± 0.25 Nm {0.15 ± 0.025 kgm}
a Tighten the head cover to the following torque.

3 Head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
16 WA200-6
Measuring blow-by pressure 1 5. While pressing the brake pedal, set the direc-
tional lever or switch to the F (forward) or R
a Necessary tools (reverse) position.
Symbol Part No. Part Name k Keep pressing the brake pedal securely.
D 799-201-1504 Blow-by checker

6. Press the accelerator pedal gradually to the
a Measure the blow-by pressure under the fol- high idle. While running the engine at HST
lowing condition. stalling and hydraulic stalling, and measure the
q Engine coolant temperature: blow-by pressure.
Within operating range a Do not keep stalling the HST for more
q Hydraulic oil temperature: than 20 seconds. Take care that the HST
Within operating range oil temperature will not exceed 120°C.
q HST oil temperature: a Normally, the blow-by pressure should be
Within operating range measured while the engine is operated at
the rated output. In the field, however, an
1. Stop the engine. Install nozzle [1] and hose [2] approximate value can be obtained by
of blow-by checker D to blow-by hose (1) and HST stalling and hydraulic stalling.
connect them to gauge [3]. a If it is impossible to run the engine at the
rated output or HST stalling and hydraulic
stalling, measure while the engine is run-
ning at high idle. The value obtained in
this case is about 80% of the blow-by
pressure at the rated output.
a Precaution for measuring blow-by pressure
The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
to the abnormal blow-by pressure.
a Blow-by hose (1) comes out from the rear

left of the engine and its end is fixed to the
machine lower frame.
7. Remove the measurement tool after the mea-

surement, and make sure that the machine is
back to normal condition.
2. Start the engine and increase the engine cool-

ant temperature to the operating range.
3. Press the left brake pedal securely.
4. Release the parking brake.
WA200-6 17
Testing engine oil pressure 1 3. Install nipple [1] of hydraulic tester E1 and con-
nect it to hydraulic tester E2.
a Necessary tools
1
E 790-261-1204 Digital hydraulic tester
2 799-101-5160 Nipple
k Stop the machine on a level ground and

lower the work equipment to the ground,
and then lo ck th e tires secu rely with
chocks.
a Measure the engine oil pressure under the fol-
lowing condition.
q Engine coolant: Within operating range
4. Start the engine and increase the coolant tem-
1. Open the engine right side cover and remove perature to the operating range.
heat insulation plate (1) above the oil filter.
5. Measure the engine oil pressure at low idle
and high idle engine speeds.
2. Remove oil pressure pickup plug (2) of the

engine oil filter.
6. After finishing measurement, remove the mea-
suring instruments and return the removed
parts.
18 WA200-6
Measuring intake air (boost) 2. Measurement with measuring tool

pressure 1 1) Open the engine right side cover.
2) Remove air boost pressure pickup plug (1)
a Necessary tools (R1/8).
F 799-201-2202 Boost gauge kit
k When installing and removing the measur-

ing instruments, take care not to touch a
hot part of the engine.
k Put chocks under the tires securely.
k When measuring, check that there are no
persons around the machine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
q Engine coolant temperature:
q Hydraulic oil temperature:
Within operating range 3) Install nipple [1] in boost gauge kit F and
q HST oil temperature: connect pressure gauge [2].
1. Measurement with monitoring function

1) Referring to “Special functions of machine
monitor (EMMS)”, select the real-time
monitoring function in the service mode.
2) Display “CHG PRESS-A” in the monitoring
functions of the machine monitor.
a Monitoring item
Code No. 36500: CHG PRESS-A (Boost
pressure)
4) Start the engine and increase the coolant

temperature to the operating range.
5) Run the engine at medium or higher
speed to drain the oil from the hose.
a Insert the connecting parts of the
gauge and hose about a half and
open the self-seal on the hose side
repeatedly, and the oil will be drained.
a If Pm kit (A) is available, you may
drain the oil by using the oil draining
coupling (790-261-1130) in that kit.
3) Press the accelerator pedal gradually to a If the oil is left in the hose, the gauge
the high idle and measure the boost pres- does not work. Accordingly, be sure
sure when HST stalling and hydraulic to drain the oil.
stalling. 6) Press the left brake pedal securely.
a Do not keep the HST stalled for more that 7) Release the parking brake.
20 seconds so that the HST oil tempera- 8) While pressing the brake pedal, set the
ture will not exceed 120°C. directional lever to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal
securely.
WA200-6 19
9) Press the accelerator pedal gradually to

the high idle. While running the engine at
high idle, stall the HST and hydraulic work
equipment and measure the intake air
pressure (boost pressure).
a Do not keep stalling the HST for more
than 20 seconds. Take care that the
120°C.
10) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
20 WA200-6
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
WA200-6 21
Measuring fuel pressure 1 2) Install adapter G2 and nipple [1] of

hydraulic tester G1 and connect them to
a Necessary tools oil pressure gauge [2].
Symbol Part No. Part name a Use the oil pressure gauge of 2.5
MPa {25 kg/cm2}.
1
790-261-1204 Digital hydraulic tester
Adapter
6732-81-3170
2 (10 × 1.0 mm o PT1/8)
G
6215-81-9710 O-ring
3 799-401-2320 Hydraulic tester
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit

a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel 3) Run the engine at low idle and measure the
main filter to the supply pump and in the return pressure in the fuel low-pressure circuit.
circuit between the supply pump/common rail/ a If the pressure in the fuel low-pres-
injector and fuel tank. sure circuit is in the following range, it
k Since the pressure in the high-pressure cir- is normal.
cuit from the supply pump through the
common rail to the fuel injector is very 0.3 – 1.1 MPa
During cranking
high, it cannot be measured. {3.1 – 11.3 kg/cm2}
0.5 – 1.3 MPa
1. Measuring pressure in fuel low-pressure At low idle
{5.1 – 13.3 kg/cm2}
circuit
1) Remove fuel pressure pickup plug (1) k If the engine cannot be started, you
from the fuel main filter. may measure the fuel pressure
while rotating the engine with the
starting motor. Do not rotate for
more than 20 seconds continu-
ously, however, for protection of
the starting motor.
4) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Fuel pressure pickup plug:
10 ± 2 Nm {1 ± 0.2 kgm}
22 WA200-6
2. Checking fuel return circuit pressure 3. Measuring fuel negative-pressure circuit

1) Disconnect quick coupler (4) of the return pressure
hose connected to the fuel filter of fuel 1) Remove joint bolt (2) of fuel hose (1)
return manifold (3). between the prefilter and supply pump.
2) Install adapter [4] of hydraulic tester G1

2) Connect fuel hose (1) to supply pump (3)
between return manifold (3) and quick
by tool G4 instead of joint bolt (2).
coupler (4) and install hydraulic tester G1
a When installing tool G4, fit the gaskets to
to the center with nipple [1].
both sides of the fuel hose joint.
a Adapter [4]: 795-790-5200
3 Tool G4:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Connect tool G5 to tool G4.
3) While running the engine at low idle, mea-

sure the fuel return circuit pressure.
a If the fuel return circuit pressure is in
the following standard range, it is nor- 4) Run the engine and measure the circuit
mal. negative pressure at high idle.
Circuit standard negative pressure:
Low idle and Max. 0.02 MPa
Max. –50.7 kPa {–380 mmHg}
cranking {Max. 0.19 kg/cm2}
5) If the negative pressure is higher than the
k
standard pressure, the fuel prefilter may
If the engine cannot be started, you
be clogged. In this case, replace the fuel
may measure while cranking the
prefilter and measure again.
engine with the starting motor. Do
not crank the engine for more than
measuring instruments and return the
continuous 20 seconds to protect
removed parts.
3 Joint bolt (2):
it, however.
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
4) After finishing work, remove the used
WA200-6 23
Measuring fuel return rate and

leakage 1
a Necessary tools
Symbol Part No. Part name
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
6754-71-5350 Washer
H Commercially
4 Measuring cylinder
available
Commercially
5 Stopwatch
available
6
Commercially
Hose (Inside diameter 14 mm)
4) Crank the engine for 30 seconds and
available measure the delivery with measuring cyl-
inder H4.
a Prepare receiving pan of about 20 liters to a Adjust the route of the test hose so
receive the fuel flowing out during measure- that it will not slacken and put its end
ment. in receiving pan.
a Do not crank the engine for more than
k Put chocks under the tires securely. 30 seconds to protect the starting
k When measuring, check that there are no motor in any case other than this
persons around the machine. measurement.
a If the supply pump delivery is in the
1. Measuring supply pump delivery following standard range, it is normal.
1) Open the engine right side cover.
2) Loosen 2 clamps (2) of supply pump dis- At cranking speed
Min. 75 cc
(125 rpm)
charge tube (1) to disconnect tube (1).
At cranking speed
Min. 90 cc
(150 rpm)
3) Install test hose H6 to the nipple on the

discharge side of the supply pump.
a Fix the hose with a wire etc. 5) After finishing measurement, remove the
a Adjust the route of the test hose so measuring instruments and return the
that it will not slacken and put its end removed parts.
in receiving pan. 3 Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
3 Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
24 WA200-6
2. Measuring return rate from supply pump 5) Run the engine at low idle and measure
1) Open the engine right side cover. the return rate in 25 seconds with measur-
2) Disconnect return hose (1) of the supply ing cylinder H4.
pump. a If the return rate from the supply
a The return hose is connected by a pump is in the following range, it is
quick coupler. normal.
At low idle Max. 400 cc
k If the engine cannot be started, you

may measure the return rate while
rotating the engine with the start-
ing motor. Do not rotate for more
than 25 seconds continuously,
however, for protection of the start-
ing motor.
3) Install connector H3 and cap nut [1] of

tester kit H1 to the return hose to stop the
fuel from flowing out.
4) Connect test hose [2] of tester kit H1 to
the supply pump.
a Lay the test hose so that it will not
slacken and put its end in the receiv-
ing pan.

parts.
a When measuring the leakage from
the pressure limiter or finishing the
measurement: Return the removed
parts to their original positions.
a When measuring the leakage from
the injector: Leave the removed parts
as they are and keep the test hose
end in the receiving pan.
WA200-6 25
3. Measuring leakage from pressure limiter

1) Open the engine right side cover.
2) Disconnect return hose (2) from the pres-
sure limiter.

parts.
3) Install removed connector bolt (3) and cap 4. Measuring injector return rate
nut [1] of tester kit H1 to the return hose to a The injector return rate must be measured
stop the fuel from flowing out. with the pressure limiter return hose con-
4) Install test hose [2] of tester kit H1 to the nected. Accordingly, check that no fuel
common rail. leaks from the pressure limiter in advance.
a Lay the test hose so that it will not 1) Referring to "Measuring supply pump
slacken and put its end in the receiv- return rate", set the supply pump under
ing pan. the condition for measurement.
a While the injector return rate is mea-
sured, the fuel flows out of the supply
pump. Accordingly, put the test hose
end on the supply pump in an oil
receiving pan.
2) Disconnect 2 quick couplers of return
hose (4).
5) Run the engine at low idle and measure

the leakage in 1 minute with measuring
cylinder H4.
a If the leakage from the pressure limiter
is in the following range, it is normal.
0 cc
At low idle
(No leakage)
26 WA200-6
3) Install cap nut [1] of tester kit H1 to the

return hose T-joint to prevent the fuel from
flowing out.
the supply pump.
the other quick coupler.
a Set the test hose so that it will not
slack and put its end in the receiving
pan.
6) Run the engine at low idle and measure

the return rate in 1 minute with measuring
cylinder H4.
a If the return rate from the injector is in
the following range, it is normal.
During cranking Max. 90 cc
At low idle Max. 120 cc
k If the engine cannot be started, you

may measure the return rate while
rotating the engine with the start-
ing motor. Do not rotate for more
than 20 seconds continuously,
however, for protection of the start-
ing motor.

parts.
WA200-6 27
Bleeding air from fuel circuit 1

a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
1. Fill the fuel tank with fuel.
2. Open the right side cover of the engine.
3. Turn feed pump knob (1) to the left to pull it out

and operate it forward and backward.
a Keep the operation of the knob until
becomes hard to operate.
a The plug at the top of the fuel main filter
does not need to be removed.
4. After bleeding air, push in knob (1) and turn it

to the right to fix it.
28 WA200-6
Testing leakage in fuel system 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If fuel leakage is recognized, repeat the
After testing the fuel system or removing procedure from step 1 after repairing the
its parts, test it for fuel leakage according leakage.
to the following procedure. a If no fuel leakage is detected, check is
a Clean and degrease the engine and the parts completed.
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.
4. Run the engine at low idle.

leakage.
for fuel leakage.
leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
leakage.
8. Start the engine and stall the HST or relieve

the hydraulic pump to apply some load on the
engine.
WA200-6 29
Handling reduced cylinder mode Handling no-injection cranking

operation 1 operation 1
a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q When a machine or engine has been stored for
lows. a long time, implementing the no-injection
cranking before starting the engine lubricates
1. This operation is used to find out a cylinder the engine parts and thus prevents its seizure.
which does not output power normally (or, a The no-injection cranking operation is set from
combustion in it is abnormal). the service mode of the machine monitor. For
details, see “Special functions of machine
2. When a cylinder is selected for the reduced monitor (EMMS)”, “6. No-injection cranking
cylinder mode operation, if the engine speed function”.
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects. The possible defects
are as follows.
q Compression leakage through cylinder
head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is
set from the service mode of the machine
monitor.
For details, see “Special functions of
machine monitor (EMMS)”, “5. Reduced
cylinder mode operation function”.
30 WA200-6
Handling controller voltage circuit Check of muffler and muffler

1. When disconnecting or connecting a connector stack for looseness and damage 1
between the engine controller and engine, be 1. Check the muffler and muffler stack visually for
sure to turn the starting switch OFF. a crack and damage. If any part is damaged,
replace it.
2. If a T-adapter is inserted in or connected to a
connector between the engine controller and 2. Check the mounting bolts and nuts of the muf-
engine for troubleshooting, do not start the fler and muffler stack for looseness. If they are
engine. loosened, retighten them.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
WA200-6 31
Check of muffler function 1 Check of installed condition of

q Check the muffler for abnormal sound and dif- cylinder head and manifolds 1
ference in sound from a new machine. If it Check the installed condition of the cylinder head
makes abnormal sound, repair it, referring to and air intake manifold and exhaust manifold. If
the Troubleshooting Volume. they are loosened, retighten them.
a For the tightening torque, see the "Disassem-
bly and assembly" volume.
32 WA200-6
Check of engine piping for Testing and adjusting air condi-

damage and looseness 1 tioner compressor belt tension 1
Air intake and exhaust systems:
Testing
Check the piping for damage, looseness of the
q Press the middle point between air conditioner
mounting bolts and nuts, and suction of air and
compressor pulley and drive pulley with a finger
leakage of exhaust gas through the joints. If it
and measure deflection (a) of the belt.
is loosened or damaged, retighten or repair.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Standard deflection (a): 8 – 11 mm
Cooling system:
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or dam-
aged, retighten or repair.
Fuel system:
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or dam-
aged, retighten or repair.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen compressor bracket upper mounting

bolts (1) and lower fixing nut (2).
2. Loosen locknut (3) and adjust the belt tension

by turning adjustment bolt (4).
3. After the tension is adjusted to the reference

value, tighten locknut (3), fixing nut (2) and
compressor bracket mounting bolts (1).
WA200-6 33
Replacing alternator belt 1 4. Replace alternator belt (3).

q Check each pulley for breakage and crack.
a The auto-tensioner is provided for the alterna-
tor belt. Thus, testing and adjustment of the
belt is usually no necessary.
a Remove air conditioner compressor belt before
replacing the alternator belt.
k Stop the machine on a flat ground and
lower the work equipment to the ground.
1. Open the engine left side cover.
2. Remove partition plate (1). For details, see

Disassembly and assembly volume, "Removal
and installation of radiator assembly".
3. Apply wrench (a) to part A (width across flats T

12.7 mm) of tensioner assembly (2) and turn it
in the arrow direction to decrease the tension
of fan belt (3).
k Make sure that the wrench (a) is
secured at portion (A) before rotating
it. (The spring of tensioner assembly
(2) is strong. If the wrench is loosely
inserted, the wrench may accidentally
come off while being rotated and it is
extremely dangerous.)
k After removing alternator belt (3), return
tensioner assembly (2) slowly with care.
k Be careful not to get your fingers
caught between the pulley and alterna-
tor belt (3) during work.
34 WA200-6
WA200-6 35
SEN03732-00

© 2007 KOMATSU
All Rights Reserved
36
SEN03733-00
WA200-6
WA200-6 70001 and up

Checking operating force of accelerator pedal ............................................................................................... 3
Checking directional lever............................................................................................................................... 4
Testing and adjusting HST oil pressure .......................................................................................................... 5
Testing clutch control pressure ....................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure................................................................................................... 12
Bleeding air from steering circuit................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Measuring brake pedal ................................................................................................................................. 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Measuring brake performance ...................................................................................................................... 19
Testing and adjusting accumulator charge pressure..................................................................................... 20
Testing wheel brake oil pressure................................................................................................................... 22
Testing wear of brake disc ............................................................................................................................ 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit............................................................................. 27
WA200-6 1
Testing parking brake performance............................................................................................................... 28

Testing and adjusting parking brake control cable ........................................................................................ 29
Measuring and adjusting work equipment control lever ................................................................................ 30
Testing and adjusting work equipment hydraulic pressure............................................................................ 31
Testing work equipment PPC oil pressure .................................................................................................... 32
Bleeding air from hydraulic circuit ................................................................................................................. 34
Releasing remaining pressure in hydraulic circuit......................................................................................... 35
Testing and adjusting bucket positioner ........................................................................................................ 36
Testing and adjusting of boom kick-out switch .............................................................................................. 38
Checking proximity switch operation pilot lamp ............................................................................................ 39
Procedure for testing diodes ......................................................................................................................... 40
Preparation work for troubleshooting for electric system .............................................................................. 42
Starting KOMTRAX terminal operations........................................................................................................ 46
Indicator lamps of KOMTRAX terminal ......................................................................................................... 50
2 WA200-6
Checking operating force of a After greasing, wipe off grease completely (No
accelerator pedal 1 grease is adhered on roller surface and roller
sliding surface).
Necessary tools
J 79A-264-0021 Push-pull scale
k Stop the machine on a level ground, lower

the work equipment to the ground, and set
chocks under the tire securely.
Testing accelerator pedal operating effort
1. Set push-pull scale J at a position 150 mm

from pedal fulcrum (a).
a Put the center of push-pull scale J in con-
tact with a point 150 mm from the pedal 5. After finishing the work, remove the measuring
fulcrum. instruments and return the removed parts.
Testing accelerator pedal operating angle
1. Start the engine.

2. Measure operating angle (α) when the pedal is
operated from the low idle position to the high
idle position.
3. Apply angle gauge [1] to accelerator pedal (1)
and measure pressing angle between low idle
angle α1 and high idle angle α2 (α = α1 – α2).
2. Start the engine, then measure the maximum

value when the pedal is pushed in from the low
idle position to the end of its travel (high idle).
3. Stop the engine.
4. If the squeak noise is heard from accelerator
pedal when checking, lubricate from grease
nipple (1) of roller shaft.
2 Roller shaft: Grease (G2-LI)
WA200-6 3
Checking directional lever 1

Necessary tools
1 79A-264-0021 Push-pull scale
K Commercially
2 Scale
available

Checking operating effort of directional lever
1. Stop the engine.

2. Install push-pull scale K1 or a spring balance
to a point 10 mm from the tip of the directional
lever, then measure the operating effort when
the lever is pulled in the direction of actuation.
a Carry out the measurement in each speed
range.
Checking travel of directional lever
1. Stop the engine.

2. Make mark (a) on the center of the knob of the
directional lever, then measure the travel with
scale K2 when the lever is operated in the
direction of actuation.
4 WA200-6
Testing and adjusting HST oil

pressure 1
Necessary tools
799-101-5002 Analog type hydraulic tester
L
790-261-1204 Digital type hydraulic tester
k Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.
a HST oil temperature when measuring: Within
operating range
a The high-pressure relief pressure is the same
as the safety pressure of the main circuit, so it 3. Measure the high-pressure cut-off oil pressure
cannot be measured. (Normally, the cut-off under the following conditions.
valve is actuated first, so it does not rise to the 1) Lower the bucket to near the ground, then
safety valve set pressure) drive the machine forward and thrust the
bucket into the stockpile of soil or rock
Testing (portion a).
a Set the directional lever to FOR-
Testing high-pressure cut-off oil pressure WARD and the speed selector switch
[Testing with monitoring function] to 2nd and traction control switch to
1. Referring to “Special functions of machine ON.
monitor (EMMS)”, select the real-time monitor-
ing function in the service mode.
2. Display “HST PRESS” among the monitoring
items of the machine monitor.
a Monitoring item
Code No. 32600: HST PRESS (HST oil
pressure)
[Testing with tools]
1. Open the engine hood side cover.
2. Install oil pressure gauge L (60 MPa {600 kg/
cm2}) to pressure measurement nipple (1).
q Nipple (1): For FORWARD circuit
(port: MA)
q Nipple (2): For REVERSE circuit
(port: MB) 2) Run the engine at full throttle and press
a Install the oil pressure gauge L to nip- the bucket into part “a” until the machine
ple (1) of the forward circuit. does not move forward.
k Carry out the measurement on
hard ground where it is difficult for
the tires to slip.
3) Keep the engine running at full throttle,
check that the tires are not turning, then
measure the oil pressure.
4) After finishing the work, remove the mea-
suring instruments and return the
removed parts.
WA200-6 5
Testing low-pressure relief pressure (basic

pressure of work equipment PPC circuit)
[Testing with monitoring function]
See “Testing high-pressure cut-off oil pressure”.
[Testing with tools]
1. Remove low-pressure relief pressure mea-
surement plug (4) (10 mm, P = 1.25 mm) from
under the machine.
a The oil pressure pickup plug is installed to
the accumulator bottom near the lower
right of the transfer on the right side of the
rear frame.
2. Remove servo piston control pressure mea-

surement plug (6) (DA pressure) (10 mm, P =
1.25 mm).
2. Install a nipple, then connect oil pressure

gauge L (6 MPa {60 kg/cm2}).
3. Install nipple L [3], then connect oil pressure

gauge L [1], L [2] (6 MPa {60 kg/cm2}).
3. Place the directional lever at N, run the engine

at high idle, and measure the low-pressure
relief pressure.
4. After finishing the work, remove the measuring
4. Place the directional lever at N, run the engine
Testing servo piston control pressure (DA pres- at high idle, and measure the control pressure
sure) when the brake pedal is depressed and when it
is released.
1. Remove floor frame cover (5) (bottom left of
a The brake pedal is connected to the inch-
operator's cab).
ing valve and controls the control pres-
sure.
6 WA200-6
Testing servo piston actuating pressure Adjusting

1. Remove servo piston actuation pressure mea-
surement plug (7) or (8) (G 1/4) (width across a The high-pressure relief pressure is also the
flats for hexagonal head wrench: 8 mm). safety pressure of the main circuit, so it cannot
q Plug (7): For FORWARD circuit (port: X1) be measured. (Normally, the cut-off valve is
q Plug (8): For REVERSE circuit (port: X2) actuated first, so it does not rise to the safety
valve set pressure)
Adjusting high-pressure cut-off valve
a If the high-pressure cut-off pressure is not cor-
rect, adjust high-pressure cut-off valve (9) as
follows.
1. Remove the engine hood.
2. Loosen locknut (10) of high-pressure cut-off
valve (9), then turn adjustment screw (11) to
adjust.
a Turn the adjustment screw to adjust as fol-
lows.
q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
2. Install a nipple L [3], then connect oil pressure COUNTERCLOCKWISE.
gauge L [1], L [2] (6 MPa {60 kg/cm2}). a Amount of adjustment for one turn of
adjustment screw: 9.1 MPa {93 kg/cm2}
3. After adjusting, tighten locknut (10).
3 Locknut: 37.2 Nm {3.8 kgm}
3. Measure the servo piston actuating pressure

under the following conditions.
1) Set the gear speed selector switch in the
“1st” position and set the travel speed
control dial in the “1” position on the low-
est speed side.
2) Measure the oil pressure while driving for-
ward at full throttle (4 km/h). Similarly,
measure while driving in reverse.
a Do not press the brake pedal.
a After completion of adjustment, repeat the

measurement procedure to check the
high-pressure cut-off oil pressure again.
WA200-6 7
Adjusting low-pressure relief valve Adjusting DA valve

a If the low-pressure relief pressure is not cor- a If the servo piston control pressure is not cor-
rect, adjust the low-pressure relief valve as fol- rect, adjust the DA valve as follows.
lows. 1. Remove the engine hood.
1. Remove the engine hood. 2. Loosen locknut (17) of DA valve (16), then turn
2. Loosen low-pressure relief valve (12) and lock- adjustment screw (18) to adjust.
nut (14) and rotate adjustment screw (15) to a Turn the adjustment screw to adjust as fol-
adjust the pressure. lows.
a Turn the adjustment screw to adjust as fol- q To DECREASE pressure, turn
lows. CLOCKWISE.
q To INCREASE pressure, turn q To INCREASE pressure, turn
CLOCKWISE. COUNTERCLOCKWISE
q To DECREASE pressure, turn a Amount of adjustment for one turn of
COUNTERCLOCKWISE adjustment screw: 0.34 MPa {3.5 kg/cm2}
a Amount of adjustment for one turn of 3. After adjusting, tighten locknut (17).
adjustment screw: 0.38 MPa {3.9 kg/cm2} 3 Locknut: 64.7 Nm {6.6 kgm}
3 Locknut: 69.6 Nm {7.1 kgm}

measurement procedure to check the con-
a After completion of adjustment, repeat the trol pressure again.
measurement procedure to check the low-
pressure relief pressure again.
8 WA200-6
Testing clutch control pressure 1

Necessary tools
1
M
799-401-3100 Adapter
2
02896-11008 O-ring
k When removing the measurement plug and

disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank. 3. Set the speed selector switch to 3rd or 4th,
travel at a speed of at least 10 km/h, and mea-
1. Remove the rear frame left side cover (1). sure the clutch inlet pressure (clutch solenoid
valve output pressure).

2. Disconnect clutch solenoid valve output pres-

sure (clutch inlet pressure) hose (2), then con-
nect hydraulic tester M1 (6 MPa {60 kg/cm2})
and adapter M2 (Hose size: For # 02).
WA200-6 9
Testing and adjusting steering Measuring operating force of steering wheel

wheel 1
a Measurement conditions
Necessary tools q Road surface:
Symbol Part No. Part Name Flat, horizontal, dry paved surface
N 79A-264-0021 Push-pull scale
Within green range on engine coolant
temperature gauge
Measuring play of steering wheel q Hydraulic oil temperature:
45 – 55°C
a Measurement conditions q Tire inflation pressure:
q Engine speed: Stopped Specified pressure
q Machine posture: Facing straight forward q Engine speed:
Low idle (bucket empty)
1. Move the steering wheel (1) 2 or 3 times lightly
to the left and right, check that the steering 1. Install push-pull scale N to the steering wheel
mechanism is at the neutral position, then knob (2).
make mark (A) on the outside frame of the
machine monitor. 2. Start the engine.
2. Turn the steering wheel to the right, and make a After starting the engine, raise the bucket
mark (B) at the position where the operating approx. 400 mm and remove the frame
effort starts to become heavy. lock bar.
3. Pull push-pull scale N in the tangential direc-

tion and measure the value when the steering
wheel moves smoothly.
a Do not use the valve when the steering
wheel starts to move.
3. Turn the steering wheel to the left in the oppo-

site direction from Step 2, and make a mark at
the point where the operating effort becomes
heavy (when the steering valve lever starts to
mov e). Then measure the distance in a
straight line between marks (B) and (C).
10 WA200-6
Measuring operating time for steering wheel
q Road surface:
Flat, horizontal, dry paved surface
Within green range on engine coolant
temperature gauge
q Hydraulic oil temperature:
45 – 55°C
q Tire inflation pressure:
Specified pressure
q Engine speed
Low idle and high idle
1. Start the engine.

a After starting the engine, raise the bucket
approx. 400 mm and remove the frame
lock bar.
2. Operate the steering wheel to the end of its
stroke to turn the machine to the left or right.
3. Measure the time taken to operate the steering
wheel to the end of the stroke to the right or
left.
a Turn the steering wheel smoothly at a
speed of 60 rpm.
a Carry out the measurements both at low
idle and high idle, and to both the left and
right.
WA200-6 11
Testing and adjusting steering oil 3. Fit a nipple P [3] to the steering circuit pressure
pressure 1 measurement plug hole, then install oil pres-
sure gauge P [1], P [2] (40 MPa {400 kg/cm2}).
Necessary tools
P
a Measuring condition
q Hydraulic oil temperature:45 – 55°C
q Engine speed: High idle
Measuring main relief pressure
1. Fit frame lock bar (1) to the frame.
4. Start the engine, run the engine at high idle,

then turn the steering wheel to the left or right
and measure the pressure when the relief
valve is actuated.
2. Remove oil pressure pickup plug (2) of the

steering cylinder circuit.
12 WA200-6
Adjusting main relief pressure 4. Loosen lock screw (5), and then turn adjust-
ment screw (6) to adjust.
1. Stop the engine. a Turn the adjustment screw to adjust as fol-
2. Remove cover (1) at the lower right of the lows.
operator's cab. q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
COUNTERCLOCKWISE.
a Pressure adjustment for one turn of
adjustment screw: Approx. 6.9 MPa {70
kg/cm2}
a Tool [1] for adjusting adjustment screw:
Size 7/32 inch, hexagonal
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
rately.
3 Adjustment screw (6):
2.3 – 6.8 Nm {0.23 – 0.69 kgm}
3 Lock screw (5):
3. Disconnect hose (3) and fitting (4) connected 14.7 ± 2 Nm {1.5 ± 0.2 kgm}
to port (T) of the priority valve (2).

WA200-6 13
Bleeding air from steering circuit1

a Bleed the air from the circuit as follows if the
steering valve or steering cylinder have been
removed and installed again.
1. Start the engine and run at idle for approx. 5

minutes.
2. Run the engine at low idle and turn 4 – 5 times

to the left and right.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not
to relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at low idle and operate the pis-

ton to the end of its stroke to relieve the circuit.
14 WA200-6
Testing hydraulic fan 1 3. Connect the cable of probe [2] to tachometer

[4].
Necessary tools
Symbol Part No. Part Name Tachometer kit Q1
1 799-205-1100 Tachometer KIT
2
Q 790-261-1204 Digital type hydraulic tester
799-401-3300 Adapter
3
02896-11012 O-ring

k When removing the measurement plug and
disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
a Measurement conditions 4. Start the engine, run at high idle, and measure
q Hydraulic oil temperature: 45 – 55°C the fan speed.
a Test the fan in a place where the fan blade and
probe will not be exposed to direct sunlight or 5. After finishing the work, remove the measuring
strong light. instruments and return the removed parts.
Testing fan speed
1. Open the radiator grill.
2. Install stand [1], probe [2], and reflecting tape

[3] in the tachometer kit Q1.
WA200-6 15
Testing fan drive oil pressure
1. Open the radiator grill.

2. Disconnect hose (1), install oil pressure gauge
Q2 (40 MPa {400 kg/cm 2 }) and adapter Q3
(Hose size: For #04), and connect hose (1)
again.
3. Start the engine and measure the fan drive oil

pressure.

16 WA200-6
Measuring brake pedal 1

q Engine coolant temperature: Within green
range on engine coolant temperature gauge
q Engine speed: Low idle
1. Install push gauge [1] to the operator's foot.

a Set the push gauge at a point 150 mm
from the fulcrum of the pedal.
2. Start the engine, and measure pedal angle

“α1” when running at low idle.
3. Apply angle gauge [2] to the brake pedal and

measure pressing angle (α) between pressing
angles (α1) and (α2) (α = α1 – α2).
q Operating force at (α2): 196 N {20 kg}.
WA200-6 17
Testing and adjusting brake pedal

linkage 1
Testing
1. Check for play in linkage mounting pin (7), pin-

hole of lever (6), and lever bushing.
2. Measure length of link (1), and check that it is

within the standard value.
Standard link length (a): 184 mm
a Measure the length from the center of pin
(5) to the center of ball joint (3).
3. Measure the distance of movement of rod (8)

and check that clearance (b) is within the stan-
dard value.
Standard clearance (b): 0 – 0.3 mm
a When doing this, check that the brake
pedal is in contact with the stopper.
Adjusting
Adjusting link length (a)

1. Remove pin (5) and ball joint (3), then remove
rod (1).
2. Loosen locknut (4), then turn yoke (2) and ball
joint (3) to adjust the length.
3. After adjusting the length of link (a), connect it
to the brake pedal.
a Standard value (a): 184 mm
Adjusting clearance (b)

1. Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder piston,
then turn rod (8) back 1/4 turn.
2. Tighten locknut (7).
a Standard value (b): 0 – 0.3 mm
18 WA200-6
Measuring brake performance 1
9JF01100
q Road surface:
Flat, horizontal, dry paved surface
q Travel speed:
20 km/h when brakes are applied
(Tire size: 17.5 – 25)
35 km/h when brakes are applied
(Tire size: 20.5 – 25)
q Tire inflation pressure:
Specified pressure
q Delay in applying brakes:
0.1 sec
q Specified operating force:
322 N {33 kg}
Measurement method
1. Start the engine and drive the machine.
2. Set the speed selector switch to 4th and drive

the machine.
3. When the travel speed reaches “Measurement

condition speed”, depress the left brake pedal
with the specified operating force.
a Before carrying out this operation, deter-
mine the run-up path and the point for
applying the brakes, then apply the brakes
when the machine reaches that point.
4. Measure the distance from the point where the

brakes were applied to the point where the
machine stopped.
a Repeat this measurement three times and
take the average.
WA200-6 19
Testing and adjusting

accumulator charge pressure 1
Necessary tools
R

Measuring
4. Measure the accumulator charge cut-in pres-
q Hydraulic oil temperature: 45 – 55°C sure. Start the engine, run the engine at low
k Stop the engine, then depress the brake idle, and measure the oil pressure when the
pedal at least 100 times to release the pres- brake pressure caution lamp on the monitor
sure inside the accumulator circuit. panel goes out.
q Cut-in pressure:
1. Remove the rear frame left side cover (1). 5.9 +0.2 +2
0 MPa {60 0 kg/cm }
2
5. Measure the accumulator charge cut-out pres-

sure.
a After the accumulator charge cut-in is
actuated, measure the oil pressure when
the indicator of the oil pressure gauge has
risen and suddenly starts to drop.
q Cut-out pressure:
9.8 +0.98
0 MPa {100 +10
0 kg/cm }
2

2. Remove plug (2).
3. Install measurement nipple and oil pressure

gauge R (40 MPa {400 kg/cm2}).
20 WA200-6
Adjusting
a When the accumulator charge cut-out pres-

sure is adjusted, the cut-in pressure also
changes in proportion to the ratio of the valve
area.
1. Loosen locknut (4) of unload relief valve (accu-

mulator charge cut-out valve) (3), then turn
adjustment screw (5) to adjust.
a Turn the adjustment screw to adjust as fol-
lows.
q To RAISE pressure, turn CLOCK-
WISE
q To LOWER pressure, turn COUN-
TERCLOCKWISE
adjustment screw: 1.45 MPa {14.8 kg/cm2}

3 Locknut: 11.8 – 16.7 Nm {1.2 – 1.7 kgm}

measurement procedure given above to
check the accumulator cut-in pressure
and cutout pressure again.
WA200-6 21
Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a The right side is shown as an example in
a Necessary tools the figure.
3. Remove union (3) and install adapter S4 and
1 793-605-1001 Brake test kit
nipple S5.
2 790-101-1430 Coupler a Use the O-ring fitted to the union.
3 790-101-1102 Pump
S 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
T 793-463-1100 Stopper

k Apply the parking brake and put chocks
under the tires securely.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measuring condition.
q Engine coolant temperature: Within oper-
ating range
q Hydraulic oil temperature: Within operat-
ing range
1. Remove front frame inspection cover (1).

k When raising the lift arm to remove the
inspection cover, place a stand [1]
under it to support securely.
Instead, you may set stopper T to the
lift arm cylinder to prevent the work 4. Connect brake test kit S1 to nipple S5.
equipment from lowering. a For the composition and connection, see
the figure on the following page.
5. Connect hose [1] and loosen bleeder screw (4)

to bleed air.
a Operate tool S3 to bleed air.
22 WA200-6
Composition and connection diagram of brake test kit S
WA200-6 23
6. Tighten bleeder screw (4), operate pump S3 to

increase the pressure to 4.1 MPa {42 kg/cm2},
and tighten stop valve [2] (a component part of
S1).
7. Leave the brake circuit pressurized for 5 min-

utes and check lowering of the pressure.
a If the hose is moved while the pressure is
me as ur ed , the p re s su r e flu c tua tes .
Accordingly, do not move the hose.
a After testing the pressure, operate pump
S3 to lower the pressure in brake test kit
S1, and then remove brake test kit S1.
a After finishing testing, install the brake
tube and bleed air from the brake circuit.

24 WA200-6
Testing wear of brake disc 1 2. While pressing the brake pedal, insert testing
gauge U in the inspection plug hole and pinch
Necessary tools the inspection projection around piston (2) and
Symbol Part No. Part name plate (3) with the inspection gauge tip.
U 418-98-31110 Testing gauge
Reference: Testing gauge U is component part
of tool kit.
a If you can pinch the inspection projection
k Stop the machine on a level ground, lower around piston (2) and plate (3) with the
the work equipment to the ground, and set inspection gauge tip, the brake disc is
chocks under the tire securely. worn more than the repair limit. In this
a There are inspection plugs on the right and left case, replace the brake disc.
sides of the front and rear axles. Check at all of
the 4 plugs similarly.
1. Remove inspection plug (1) from the axle

housing.

3 Inspection plug (1):
127.4 – 176.4 Nm {13 – 18 kgm}
WA200-6 25
Bleeding air from wheel brake 3. Connect hose [1] to bleeder screw (2) and
circuit 1 place hose [1] in the oil receive pan.
a Work on the rear side similarly from under-
Necessary tools side of the machine.
T 793-463-1100 Stopper

a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
a Bleed air from the front brake circuit and rear
brake circuit similarly (2 places each).
a When a complete bleeding is required, it is
advisable to start the operation from the brake
cylinder situated farthest from the brake pedal. 4. Press the brake pedal and then loosen bleeder
a The work on the front right side is shown as an screw (2) to bleed air.
example. Work on each brake cylinder simi- a Return the brake pedal slowly after tight-
larly. ening bleeder screw (2).
1. Start the engine to accumulate pressure in the 5. Repeat this operation until the oil flowing
accumulator and then stop the engine. through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
2. Remove front frame inspection cover (1). screw (2) while the oil is flowing.
k When raising the lift arm and removing a As accumulated pressure in the accumu-
the inspection cover, place support lator is decreased, start the engine to
stand [1] under the lift arm to support accumulate pressure in the accumulator.
the lift arm securely or set stopper T to Then bleed air using the same procedure
the lift arm cylinder to prevent the work as described above.
equipment from falling. a After finishing bleeding air, run the engine
at low idle and check the oil level in the
hydraulic tank. If the level is low, add oil up
to the specified level.

26 WA200-6
Releasing residual pressure in

brake accumulator circuit 1
k Before disconnecting any of the following
brake accumulator circuits, release resid-
ual pressure in that brake circuits.
q Piping between accumulator charge valve and

brake accumulator
q Piping between brake accumulator and brake
valve on both sides
1. Stop the engine.
2. Press the brake pedal at least 100 times to

release the pressure from the brake accumula-
tor circuit.
WA200-6 27
Testing parking brake

performance 1
a Measurement condition
q Tire inflation pressure: Specified pressure
q Road: 1/5 gradient (11° 20'), flat, and dry road
q Machine: Ready for operation
Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a
slope of 1/5 gradient with no load in the bucket.
2. Press the brake pedal to stop the machine, set

the directional lever in the N position, and stop
the engine.
3. Pull the parking brake lever fully, release the

brake pedal gradually, and check that the
machine is kept stopped.
a Measure the parking brake performance
on an uphill and a downhill.
28 WA200-6
Testing and adjusting parking Adjusting

brake control cable 1 1. Release the parking brake.
a Check that the pawl of the parking brake
Necessary tools lever is at the lowest position.
2. Loosen locknut (2) and remove clevis pin (3).
V 79A-264-0021 Push-pull scale
3. Pull parking brake lever (4) on the transfer side
Testing in the release direction. (Add the play of the
1. Install push-pull scale V to a position at dimen- parking brake lever to the upper side, how-
sion (a) from the end of parking brake lever (1) ever.)
(excluding the button) and pull it with a force of
about 294 N {about 30 kg}. 4. Under the above condition, tighten clevis (5) to
q Dimension (a): 55 mm match its hole to the hole of parking brake
lever (4).
2. If the parking brake lever is pulled by 9 teeth or
more, check the fixing parts of the parking 5. Install clevis pin (3) and tighten locknut (2).
brake control cable (on both lever side and 3 Locknut: 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
brake side) for looseness. If the fixing parts are a After finishing adjustment, pull parking
loosened, tighten them, and then perform the brake lever (1) again with a force of about
following adjustment. 294 N {about 30 kg} and check that it trav-
els 7 – 8 clicks.
WA200-6 29
Measuring and adjusting work Measuring travel of work equipment control

equipment control lever 1 lever
Measure the travel at each position when operating
Necessary tools
the work equipment control lever.
Symbol Part No. Part Name a Mark the lever knob and use a scale W2 to
1 79A-264-0021 Push-pull scale measure.
a If the stroke is not within the standard value,
W Commercially
2 Scale check for play in the work equipment PPC
available valve.
k Install the frame lock bar to the frame.

a Measuring condition
q Engine coolant temperature: Operating range
of engine coolant thermometer
q Hydraulic oil temperature: 45 – 55°C
q Engine speed: Low idle
Measuring operating effort of work equipment

control lever
Install tool W1 to the work equipment control lever
and secure it in position.
a Install tool W1 to the center of the knob.
a Operate the control lever at the same speed as
for normal operations, and measure the mini-
mum value for the effort needed to operate the
knob.
30 WA200-6
Testing and adjusting work Adjusting

equipment hydraulic pressure 1 a Always stop the engine before adjusting the oil
Necessary tools pressure.
k When carrying out the operation with the
lift arm raised, set support [1] or lift arm
799-101-5002 Analog type hydraulic tester drop prevention stopper T in position
X
790-261-1204 Digital type hydraulic tester before starting the operation.
T 793-463-1100 Stopper
1. Remove front frame inspection cover (1).

the pressure inside the hydraulic tank, then
operate the control levers several times to
release the remaining pressure in the
hydraulic piping.
Measuring condition
Measuring
1. Install hydraulic tester X (40 MPa {400 kg/

cm2}) to the oil pressure measurement nipple.
2. Remove cap nut (2) of relief valve (5).
3. Loosen locknut (3) of relief valve (5), then turn

adjustment screw (4) to adjust.
a Turn the adjustment screw to adjust the
set pressure as follows.
q TIGHTEN to INCREASE pressure
q LOOSEN to DECREASE pressure
adjustment screw: Approx. 2.43 MPa
{Approx. 24.8 kg/cm2}
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
2. Start the engine, raise the lift arm approx. 400 rately.
mm, run the engine at high idle, then operate
the control lever to tilt back the bucket, and
measure the pressure when the relief valve is
actuated.

WA200-6 31
Testing work equipment PPC oil

pressure 1
Necessary tools
Y
T 793-463-1100 Stopper

the pressure inside the hydraulic tank.
Then operate the control levers several
times to release the pressure in the piping.
Measuring condition
Checking PPC valve output pressure
k When leaving the operator's seat, apply the 1. Remove the inspection cover (1) of the front
work equipment lock lever securely. frame.
k Except for measuring the oil pressure,
Testing PPC valve basic pressure when carrying out preparatory operations
with the lift arm raised, set support [1] or
1. Remove plug (4) (10 mm, P = 1.25 mm) for
lift arm drop prevention stopper T in posi-
measuring the work equipment EPC valve
tion before starting the operation.
basic pressure (same as low-pressure relief
pressure) from under the machine.
2. Remove PPC output pressure measurement

plug of the circuit to be measured, then install
2. Fit a nipple, then install oil pressure gauge Y (6 oil pressure gauge Y (6 MPa {60 kg/cm2}).
MPa {60 kg/cm2}). 3. Start the engine, then remove support [1] or
3. Start the engine. boom drop prevention stopper T.
4. Run the engine at high idle, then operate the
work equipment control lever and measure the
oil pressure.
32 WA200-6
4. Operate the work equipment control lever at

high idle and measure the oil pressure.
a A: Bucket TILT
B: Bucket DUMP
C: Lift arm RAISE
D: Lift arm LOWER

WA200-6 33
Bleeding air from hydraulic

circuit 1
Bleeding air from work equipment PPC circuit

1. Operate each work equipment lever fully and
hold it in position to relieve the circuit for
approx. 1 minute. Carry out this operation once
for each work equipment lever stroke end.
Bleeding air from cylinders

1. Start the engine and run at idle for approx. 5
minutes.
2. Run the engine at low idle, then raise and
lower the lift arm 4 – 5 times in succession.
a Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circum-
stances.
3. Run the engine at full throttle and repeat Step
2. After that, run the engine at low idling, and
operate the piston rod to the end of its stroke to
relieve the circuit.
4. Repeat Steps 2 and 3 to bleed the air from the
bucket and steering cylinders.
a When the cylinder has been replaced,
bleed the air before connecting the piston
rod.
34 WA200-6
Releasing remaining pressure in

hydraulic circuit 1
Releasing remaining pressure between each
hydraulic cylinder and control valve
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
1. Lower the work equipment to the ground, and
stop the engine.
2. Loosen the oil filler cap slowly to release the
pressure inside the tank.
3. Operate the control levers.
a When the levers are operated 5 – 6 times
to release all the remaining pressure.
Releasing remaining pressure in brake accumu-

lator circuit
a If the piping between the ACC charge valve
and brake accumulator, between the ACC
charge valve and parking brake valve, and
between the accumulator and brake valve is to
be disconnected, release the remaining pres-
sure from the circuit as follows.
1. Stop the engine.
2. Depress the brake pedal at least 100 times to
release the pressure inside the brake accumu-
lator circuit.
Releasing remaining pressure in PPC accumu-

lator circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
1. Lower the work equipment to the ground, and
stop the engine.
2. Operate the control lever 5 – 6 times to release
all the remaining pressure from the circuit.
WA200-6 35
Testing and adjusting bucket Adjusting

1. Adjusting clearance.
positioner 1 1) Adjust and secure clearance (b) between
a Measuring condition the tip of switch protector c and the sensi-
q Engine coolant temperature: White range tive surface (1) of the switch to the stan-
of engine coolant thermometer dard range with switch nuts (4).
q Hydraulic oil temperature: 45 – 55°C a Standard clearance (b): 0.5 – 1.0 mm
3 Mounting nut:
Testing 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
1. Stop the engine and check that clearance (a)
between proximity switch (1) and detection bar
(2) is in the standard range.
a Standard clearance (a): 3 – 5 mm
2) Adjust and secure clearance (a) between

the sensitive surface of proximity switch
(1) and detection bar (2) to the standard
range with the shim and mounting bolt of
2. Run the engine at same as usual working the proximity switch bracket.
speed and check the operating point. (Mea- a Standard clearance (a): 3 – 5 mm
sure 3 times and obtain the average.) a Adjust detection bar (2) with the shim
so that clearance (a) will be in the
standard range through the stroke of
the detection bar (2).
36 WA200-6
2. Adjusting installing position (stopping

position).
1) Lower the bucket to the ground and set it
to a desired digging angle, then return the
lever to the holding position and stop the
engine.
2) Loosen 2 mounting bolts (5) and adjust
the position of switch protector (3) so that
the rear end of detection bar (2) will be at
the center of the sensitive surface of prox-
imity switch (1), and then tighten 2 mount-
ing bolts (5).
3) Check again that clearance (a) between
proximity switch (1) and detection bar (2)
is 3 – 5 mm.
q The installing position may be
checked by checking the operation of
the pilot lamp of the proximity switch
with the starting switch at the ON
position. (When the pilot lamp goes
off, the bucket stops.)
a After adjusting, start the engine and oper-

ate the work equipment control lever to
check that the bucket positioner operates
at the desired position.
WA200-6 37
Testing and adjusting of boom 4. Adjust the switch so that clearance b between
kick-out switch 1 the sensing surface of the switch and plate (2)
is the standard value, then secure in position.
Testing 3 Switch mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
1. With the engine stopped, check that clearance q The installing position may be checked by
(a) between detection surface of switch (1) and checking the operation of the pilot lamp of
plate (2) is the standard value. the proximity switch with the starting
a Standard clearance (a): 3 – 5 mm switch at the ON position.
a For ON/OFF of the pilot lamp, see “Check-
ing proximity switch working pilot lamp”.
a After adjusting, start the engine, operate
the work equipment control lever and
check that the boom kickout is actuated at
the desired position.
2. Start the engine, run at high idle, and check the

actuation point.
(Check three times and take the average.)
Adjusting
1. Raise the lift arm to the desired height, then

mark the lift arm to show the position where
the center of the switch is aligned with the bot-
tom of the plate.
k Always be sure to apply the work equipment
lock lever.
2. Lower the lift arm and stop the engine.

3. Align the marks and adjust the position of the
plate so that the center of switch (1) is at the
bottom of plate (2), then secure in position with
bolt (3).
38 WA200-6
Checking proximity switch

operation pilot lamp 1
The proximity switch has a pilot lamp to indicate its

operating condition. Use this pilot lamp when
adjusting the proximity switch.
q A: Operation pilot lamp (Red)
Positional relationship between sensitive surface

Proximity switch Operation pilot lamp Remarks
of proximity switch and sensing object
Near ON Operates when center of
Bucket positioner
Far OFF switch is near
Near ON Operates when center of
Boom kick-out
Far OFF switch is far
WA200-6 39
Procedure for testing diodes 1 1. When using digital type circuit tester
1) Switch the testing mode to diode range
a Check an assembled-type diode (8 pins) and and confirm the indicated value.
independent diode (2 pins) in the following a Voltage of the battery inside is dis-
manner. played with conventional circuit testers.
a The conductive directions of the assembled- 2) Put the red probe (+) of the test lead to the
type diode are indicated on the surface of the anode (P) of and the black probe (–) to the
diode as shown in the following figure. cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
a The conductive directions of the single diode is

indicated on the surface of the diode as shown
in the following figure.
40 WA200-6
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
(–) to the cathode (N) of diode.
2] Apply the red (+) lead of the tester to
the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ev er, whe n the c onnec tion 2] is
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective (Inter-
nal short circuit)
q The pointer does not swing with both
the connections of 1] and 2]: Defec-
tive (Internal breaking of wire)
WA200-6 41
Preparation work for

troubleshooting for electric
system 1
a When carrying out troubleshooting for an elec-
tric circuit related to the machine monitor,
transmission controller, work equipment con-
troller, or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
a Disconnect and connect the connectors of spe-
cial lock types according to the following pro-
cedure.
1. Machine monitor 2) Remove cover (1).

1) Disconnect the following connectors from
cover (1).
q Connector L06: Hazard switch
q Connector L07:
Front working lamp switch
q Connector L08:
Rear working lamp switch
q Connector L09:
ECSS switch (If equipped)
q Connector L10:
Machine monitor mode selector
switch 1
q Connector L11:
Machine monitor mode selector
switch 2
3) Remove 3 bracket mounting bolts (3) of
a Pull the switch out of the cover and
machine monitor (2) and reverse the
disconnect each connector.
machine monitor.
a If you insert your hands from under
a Take care not to pull the wiring har-
the cover and disconnect a connector
ness forcibly.
forcibly, you many damage the con-
nector or switch. Take care.
42 WA200-6
4) Connect diagnosis T-adapters to connec- 3. KOMTRAX terminal

tors L24 to L30 of machine monitor (2). 1) Open right door (1) and remove console
cover (2).
2. HST controller
1) Remove cover (1) from the rear of the cab. 2) Connect diagnosis T-adapter to connec-
tor L80 of KOMTRAX terminal (3).
a If the connector cannot be discon-
nected and connected easily, remove
the KOMTRAX terminal.
a Since the connector is secured with
screws, loosen those screws before
disconnecting.
a When connecting the connector again,
tighten its screws to the specified
torque.
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
2) Connect diagnosis T-adapters to HST

connector of HST controller (2).
WA200-6 43
4. Boost pressure and temperature sensor 6. Common rail pressure sensor (FUEL RAIL
(BOOST PRESS & IMT) PRESS)
a Disconnection and connection of connector a Disconnection and connection of connector
The connector of the boost pressure and The connector of the common rail pres-
temperature sensor has a special locking sure sensor has a special locking mecha-
mechanism. Disconnect it according to nism. Disconnect it according to steps (a)
steps (a) – (b) and connect it according to – (b) and connect it according to steps (c)
steps (c) – (d) as shown below. – (d) as shown below.
Disconnection: Disconnection:
(a) Unlock – (b) Disconnect connector. (a) Unlock – (b) Disconnect connector.
Connection: Connection:
(c) Connect connector – (d) Lock. (c) Connect connector – (d) Lock.
a Removal and installation of sensor a Precautions for disconnecting connector

A torque wrench is necessary for removal The direction of the lock of the connector
and installation of the boost pressure and varies with the tightened position of the
temperature sensor. See Testing adjust- sensor and the lock may be in a direction
ing, “Troubleshooting tools table”. in which it is difficult to reset (on the under-
side or engine side).
5. Supply pump IMV solenoid (FUEL REGU- In this case, pinch the lock in direction (a)
LATOR) with bent-nose nippers (commercially
a Disconnection and connection of connector available), and the lock is reset.
The connector of the supply pump IMV Since the lock clicks when it is reset, dis-
solenoid has a special locking mecha- connect the connector after a click is
nism. Disconnect it according to steps (a) heard.
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection:
(c) Connect connector – (d) Lock.
44 WA200-6
a Precautions for connecting connector 8. Ambient pressure sensor (AMBAIR PRES-

Take care not to connect the connector SURE)
reversely. Engine Ne speed sensor (CRANK SENSOR)
Engage lock (e) on the wiring harness Engine Bkup speed sensor (CAM SENSOR)
side with triangular notch (f) on the sensor Engine oil pressure switch (OIL PRESSURE
side (Do not engage lock (e) with square SWITCH)
guide (g) on the opposite side of triangular a Disconnection and connection of connectors
notch (f)). The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, and engine oil pres-
sure switch have a special locking mecha-
nism. Disconnect them according to steps
(a) – (c) and connect them according to
steps (d) – (f) as shown below.
Disconnection: (a) Slide lever – (b) Unlock –
(c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
7. Engine coolant temperature sensor (COOL-

ANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant tem-
perature sensor has a special locking
mechanism. Disconnect it according to
steps (a) – (b) and connect it according to
steps (c) – (d) as shown below.
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection: a Removal and installation of sensor
(c) Connect connector – (d) Lock. A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See Testing adjusting, “Trouble-
shooting tools table”.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the coolant temperature
sensor. See Testing adjusting, “Trouble-
shooting tools table”.
WA200-6 45
Starting KOMTRAX terminal 3) When about 3 to 5 seconds elapsed after

operations 1 the starting switch was set to ACC, make
sure that the 7-segment indicator lamp
In the case where the KOMTRAX terminal has changes to hyphen “–” on the KOMTRAX
already been installed at the plant before ship- terminal.
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, part number, and

serial number
Notify the KOMTRAX operations administrator
of model, part number, and serial number.
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted:
a When retrofitting the KOMTRAX terminal after
shipment (retro-fitted machine), follow the
steps below.
1. Station opening check in machine side

a Complete steps 3) to 5) within 60 sec-
onds. If 60 seconds or above elapsed,
begin with step 1) again.
4) Disconnect check connector 1, and wait
1) Turn OFF the starting switch and then,
for about 3 to 5 seconds as it is.
a ft e r m a k i n g s u r e 5 s e c o n d s h a v e
a Ensure that the connector is discon-
elapsed, proceed to the next step.
nected.
2) Visually check that two check connectors
5) Reconnect check connector 1, and wait
are connected.
for about 3 to 5 seconds as it is.
q Check connector: CHK0
a If the KOMTRAX terminal detects that
q Check connector: CHK1
the connector was disconnected and
connected, the dot on the 7-segment
indicator lamp blinks a few times.
46 WA200-6
6) Make sure that the 7-segment indicator a As [Normal] is indicated, proceed to

lamp is indicated normally on the the next step.
KOMTRAX terminal. a If “–” remains displayed, execute
a If so, the 7-segment indicator lamp will steps 1) to 5) again.
indicate characters “d”, “0”, and “–”
repeatedly for 30 seconds after step 5)
was ended.
a Those characters, even if displayed
normally, will change to a character
other than hyphen “–”after 30 sec-
onds or above elapsed.
The display may change to a charac-
ter other than “0” even within 30 sec-
onds.
7) Turn the starting switch to START position

for about 3 to 5 seconds, and make sure
that the engine does not start.
a If the engine starts, re-execute the
procedure above from step 1).
a Do not return the starting switch to
OFF position.
8) Turn the starting switch from ACC position
to START position again, and make sure
that the engine starts.
9) Make sure that the KOMTRAX terminal's
indicator lamps are normally turned on.
a Move on to the next step if you can
check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trouble
and reception trouble] is indicated,
check if there is any abnormality on
the GPS antenna/cable or communi-
cation antenna/cable. If there is any
abnormality, repair it and start from
procedure 1) again.
WA200-6 47
a If [Network trouble] is indicated, 10) Turn the starting switch OFF.

check the display of [LED-C4] refer- 11) Make sure that the 7-segment indicator
ring to “Lamp display of KOMTRAX lamp is displayed normally after 5 seconds
terminal”. If the CAN is not recog- elapsed.
nized, check the CAN harness of the a When [Normal] appears, station
KOMTRAX terminal, and then if there opening check is completed.
is any abnormality, repair it and start a If [Abnormal] appears, station open-
from procedure 1) again. ing check does not end normally, so
[A]: Normal you should perform the procedure
[B]: GPS position data detection trou- above from step 1) again.
ble a If station opening check ends nor-
[C]: Reception trouble mally, it should not be rechecked.
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
s tarti ng swi tch off and star t th e
engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent commu-
nication with the ORBCOMM satellite.
The station opening check may not
be completed in doors that cause
radio waves from the satellite to be
intercepted.
48 WA200-6
2. Application for the start of use

a Application for the start of use should be
made only after the sign-up test is fin-
ished.
1) Notify the KOMTRAX operations adminis-
trator of the following information about
the machine that completed the station
opening check in the machine side.
1] Information (model, part number, and
serial number) about the machine
that completed the station opening
check in the machine side
2] Part number and serial number of
KOMTRAX terminal
3] Value of service meter when the
KOMTRAX terminal was installed (in
0.1 hours)
2) The KOMTRAX operations administrator

shall use a KOMTRAX client PC to regis-
ter the machine.
a Refer to “Manual for KOMTRAX oper-
ations administrator” for the proce-
dure.
a Now the terminal is ready for use.
WA200-6 49
Indicator lamps of KOMTRAX terminal 1
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
50 WA200-6
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
5 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
WA200-6 51
2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
*2: Blink types and blink times

Fast blink: Blinks in about 0.5-second cycle
Slow blink: Blinks in about 2.0-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
52 WA200-6
WA200-6 53
SEN03733-00

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07(01)
54
SEN03734-00
WA200-6
WA200-6 70001 and up

Adjusting machine monitor.............................................................................................................................. 2
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor.............................. 3
Special functions of machine monitor (EMMS) ............................................................................................... 5
Pm clinic inspection chart ............................................................................................................................. 59
WA200-6 1
Adjusting machine monitor 1
Layout of rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)
q Do not change the setting of the rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and
SW6) on the back side of the machine monitor.
q The switches shown in the figure are set as when the monitor is delivered.
2 WA200-6
Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor 1
1. Items to be set when sensor or controller is replaced, reassembled or added

a If any of the following components and parts is replaced or reassembled, initialize the sensors,
solenoids, etc. with the machine monitor.
a Adjust the items in alphabetical order (A –) with the machine monitor.
Replaced, reassembled, or added component or option Adjustment item
Machine monitor A, B, C
HST controller A, B
Change of tire size B
Addition or removal of option B
Adjustment item Contents of adjustment Description No.

A Selection of machine model 12 (*1)
B Selection of option 10 (*1)
C Inputting of machine serial No. 11 (*1)
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
WA200-6 3
2. Adjustment for user's needs

If the user makes the following indications or requests, change or adjust the items shown below with the
machine monitor.
Contents of indication/request Adjustment item
Change indication unit of speedometer (*2) D
Turn ECO lamp OFF E
Change interval of fan automatic reverse operation (Automatic reverse fan specification) F
Change continuance of fan automatic reverse operation (Automatic reverse fan specification) G
Travel speed is indicated too quickly/slowly H
Turn engine speed/travel speed on character display OFF J
ECSS operates at high or low travel speed K
Change display of major indication in engine speed (*3) L
Adjustment item Contents of change/adjustment Description No. (*1)

D Setting of option/Selection of speed unit (*2) 10
E Setting of option/Selection of indication of ECO lamp 10
Adjustment of sensor/Adjustment of interval of fan automatic
F 7–1
reverse operation
Adjustment of sensor/Adjustment of continuance of fan automatic
G 7–2
reverse operation
H Setting of option/Change of tire size 10
Setting of option/Change of indication of engine speed or travel
J 10
speed on normal screen of character display
M Adjustment of ECSS operation travel speed 7–5
No. 10 of
L Travel speed/engine speed display/non-display select
"Operator mode"
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*2: Change of the indication unit of the speedometer of the specification for the SI unit countries cannot be
set.
*3: When selecting “NO ADD” in optional select, cannot change travel speed/engine speed.
4 WA200-6
Special functions of machine monitor (EMMS) 1

a EMMS: Equipment Management Monitoring System
1. Machine monitor mode change switch 1

2. Machine monitor mode change switch 2
3. Character display
WA200-6 5
Normal functions and special functions of machine monitor

The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
No. No.
Operator mode Service mode
(*1) (*1)
1 Service meter display function 2 Electrical system fault history display function
2 Traction level selection function 3 Mechanical system fault history display function
3 HST function selection function 4 Real-time monitoring function
4 Odometer display function 5 Engine reduced-cylinder function
5 Maintenance monitoring function 6 No injection cranking function
6 Telephone number input function 7 Adjustment function
⇔
7 Language selection function 8 Maintenance monitoring function
8 Monitor brightness adjustment function 9 Operating information display function
Travel speed/engine speed display selecting
9 10 Optional device selecting function
function (*2)
Function of turning ON/OFF travel speed/
10 11 Machine serial number input function
engine speed display on character display (*3)
11 Action code display function 12 Model selection function
12 Failure code display function 13 Initialize function
*1: No. shows an item number in this document.

*2: q Not displayed if “SI unit specification” is set when delivered.
q Not displayed if “RPM OPT” is turned NO ADD by selecting an optional device in the service mode.
*3: Not displayed if “Travel speed/Engine speed on character display” is turned NO ADD by selecting an optional device
in the service mode.
6 WA200-6
Functions and flow of service mode

Note: Some items may not be used, depending on the setting and specification, although they are displayed
on the monitor. (For details, see the text.)
WA200-6 7
8 WA200-6
WA200-6 9
Operator mode 3. HST function selection function

a The operator mode is outlined below. While the speed range selector switch is in the
a For details of the operator mode, see “Struc- 3rd or 4th gear speed position, the reverse
ture, function and maintenance standard” or speed range can be set to 2 levels.
“Operation and Maintenance Manual”. a For details, see Operation and Mainte-
nance Manual, Operation, “Other func-
1. Service meter display function tions of machine monitor”.
If the starting switch is turned ON, the service
meter is displayed on the above line and the
engine speed is displayed on the lower line.
a If the engine speed is displayed at the
center of the monitor, the travel speed is
displayed.
4. Odometer display function

The odometer is displayed.
a For details, see Operation and Mainte-
tions of machine monitor”.
2. Traction level selection function

Press [U] switch on the ordinary service meter
display screen, and the screen to set the trac-
tion level selection function is displayed.
a If the traction control is turned ON with the
traction control switch, the traction can be
set to 3 levels.
a For details, see Operation and Mainte-
tions of machine monitor”.
a For items 3 and after, display a desired

screen with [<] or [>] switch on the “Trac-
tion level selection function” screen.
a Each time [<] or [>] switch is pressed, the
screen changes in order. Repeat either
switch until a desired screen is displayed.
10 WA200-6
5. Maintenance monitoring function 7. Language selection function

1) Filter, oil replacement time display (auto- Switch operation allows selecting a display lan-
matic display) guage of the machine monitor.
As the filter or oil replacement time draws a Functions of the service mode are con-
close, the machine monitor automatically stantly displayed in English since they are
displays its information to alert operator's exempted from the display selection func-
attention. tion.
2) Resetting replacement time (selection a A desired language is selectable from
menu) English, Japanese, German, French, Ital-
As maintenance operation for a filter or oil ian, Spanish and Swedish.
is completed, the machine monitor allows a For details, see the “Other functions of
resetting the time interval through the machine monitor” of the Operation section
switch operation. in the Operation and maintenance man-
a For details, see the “Other functions ual.
of machine monitor” of the “Opera-
tion” section in the Operation and
maintenance manual.
6. Telephone number input function

Telephone numbers are entered through the
switch operation. And modification or cancella-
tion of the phone numbers in the machine
monitor is also available through the switch
operation.
a When action code [E03] is displayed, a
phone number is displayed along with
[CALL].
a For details, see the “Other functions of
machine monitor” of the Operation section
in the Operation and maintenance man-
ual.
WA200-6 11
8. Monitor brightness adjustment function 9. Travel speed/engine speed display select-

Brightness of the machine monitor is adjustable ing function
in seven levels through the switch operation. A unit to be used for the machine monitor
a Adjustment of brightness is available in speed display is selectable from km/h and
two approaches – adjustment of the moni- MPH. It is also possible to turn on or off the dis-
tor alone and separate adjustment of the play of the travel speed and engine speed.
monitor and liquid crystal. a For details, see the “Other functions of
a For details, see the “Other functions of machine monitor” of the Operation section
machine monitor” of the Operation section in the Operation and maintenance man-
in the Operation and maintenance manual. ual.
10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
a For details, see the “Other functions of
machine monitor” of the Operation section
in the Operation and maintenance man-
ual.
12 WA200-6
11. Action code display function

If a trouble occurs, the machine monitor dis-
plays an action code corresponding to the seri-
ousness of the trouble to alert the operator for
appropriate actions.
a The figure below shows an example of the
screen on which action code [E03] and
[CALL + Telephone number] are alter-
nately displayed.
a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.
a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.
WA200-6 13
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code
failure code corresponding to the failure cur- B: Controller code
rently warned. MON: Machine monitor
a The failure codes detected in the past are HST: HST controller
divided into failures of the electrical sys- ENG: Engine controller
tem and the mechanical system and are C: The system where failure occurred
recorded as fault history. (For details, see
“Service mode”.)
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 30 seconds,
the action code display screen is automat-
ically displayed.
a For details of a displayed failure code, see

“Failure code list”.
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
14 WA200-6
Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
Reference: The service meter is displayed in mode).
English, regardless of language When the cursor is at a location other
selection in the operator mode. than the leftmost position, pressing
When using Service mode, carry out the fol- the switch returns the cursor to the
lowing special operation to switch the screen leftmost position.
display. If any switch operation is not done for
1-1. Checking screen display 60 seconds or more from ID input
Make sure that the machine monitor is set to screen, the normal screen is automat-
the operator mode and any of “Service meter”, ically turned on.
“Action code” or “Failure code” is displayed on
the screen.
1-2. Displaying ID input initial screen
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.
1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then 1-5. Selecting service mode menu
press [U] switch. a Pressing [<] and [>] switches from the
a When you have entered a wrong value to menu screen displays Service mode
a position except the highest-order digit, menus endlessly in the following order.
move to the highest-order digit using [t] a The menus are displayed in the field indi-
switch to repeat the procedure from the cated with [*] mark.
first. In this case, values that had been [1] ELECTRIC FAULT: Electrical system
entered remain as they are until modified. fault history display function
When the cursor is at the highest-order [2] MACHINE FAULT: Mechanical sys-
digit, it can move to the higher layer using tem fault history display function
[t] switch. (*1). [3] REAL-TIME MONITOR: Real-time
monitoring function
WA200-6 15
[4] CYLINDER CUT-OUT: Engine 2. Electrical system fault history display func-
reduced-cylinder function tion (ELECTRIC FAULT)
[5] NO INJECTION: No injection crank- The machine monitor records the past failures
ing function in the electric system as the failure codes. The
[6] TUNING: Adjustment function failure codes are displayed from the following
[7] MAINTENANCE MONITOR: Mainte- operations.
nance monitoring function 2-1. Selecting the menu
[8] OPERATION INFO: Operating infor- Select the ELECTRIC FAULT from the menu
mation display function screen of Service mode.
[9] OPTIONAL SELECT: Optional device a [**] field displays total number of the fault
selecting function history currently recorded (up to 20
[10] MACHINE No. SET: Machine serial cases).
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menu is indicated in the parts of [*].
2-2. Displaying fault history

Press [U] button while the menu is selected to
display the recorded fault history.
1-6. Completion of mode and function

Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the mode screen or
menu screen to be used next.
a Note, however, that [t] switch functions
as an execution key on [YES/NO] screen.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces- 2-3. Displayed fault history
sary). The electric system fault history display func-
2) When ending an operation completely: tion displays the following information.
Turn the starting switch off from the cur- A: Record number
rent state. B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Occurrence time 1 (time on service meter
at the first occurrence)
E: Occurrence time 2 (time on service meter
at the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
16 WA200-6
a For details of a displayed failure code, see 2-6. Deleting all fault history
“Failure code list” of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
2) Press [U] switch to display the ALL

CLEAR screen.
3) Select “YES” or “NO” using [<] or [>]
switch.
a The selected cursor will start flashing. If
“ YE S” is s elec ted a nd [t] s witc h is
2-4. Switching fault history display pressed, the information will be deleted. If
Pressing [<] or [>] switch while a set of fault “NO” is selected and [t] switch is
history is on the screen displays another set of pressed, deletion is cancelled and the
recorded fault history. “ Maintenanc e interval change item”
2-5. Deleting individual fault history screen is restored.
1) Press [U] switch while the target fault his- a By default, the cursor is set to NO (cancel)
tory of deletion is on the screen to turn on to prevent resetting error.
CLEAR screen. a Information of the currently occurring fail-
2) Select “YES” or “NO” using [<] or [>] switch. ure is not deletable.
“Y ES” i s s elec ted and [t] s witc h is
pressed, the information will be deleted. If
“NO” is selected and [t] switch is
pressed, deletion is cancelled and the
“Maintenance interv al c hange item”
screen is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a Information of the currently occurring fail-
ure is not deletable.
WA200-6 17
3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Occurrence time 1 (Time on service meter
history currently recorded. at the first occurrence)
E: Occurrence time 2 (Time on service meter
at the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a For details of a displayed failure code, see
“Failure code list” of next page.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
3-2. Displaying fault history

Press [U] switch while the menu is selected to
display the recorded fault history.
3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.
18 WA200-6
Failure codes table

Failure Action Category of
Troubled part/item Trouble Controller
code code record
Mechanical
2G40ZG Brake Oil pressure reduction MON E03
system
Mechanical
6091NX HST filter Clogging MON E01
system
Mechanical
989FN1 Travel speed Overrun alarm MON E02
system
Electrical
AB00L6 Alternator R system Hot short MON E01
system
Ground fault/Disconnection/Low Electrical
AB00MA Alternator R system MON E03
charge level system
Mechanical
B@BAZG Engine Oil pressure reduction ENG E03
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@BCZK Engine Low coolant level MON E01
system
Mechanical
B@C6NS Front brake High oil temperature MON E02
system
Mechanical
B@CRNS HST High oil temperature MON E02
system
Electrical
CA111 Engine controller Internal abnormality ENG E03
system
Electrical
CA115 Engine NE, Bkup speed sensor Abnormality ENG E03
system
Electrical
CA122 Charge pressure sensor Abnormally high level ENG E03
system
Electrical
CA123 Charge pressure sensor Abnormally low level ENG E03
system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03
system
Electrical
CA144 Coolant temperature sensor Abnormally high level ENG E01
system
Electrical
CA145 Coolant temperature sensor Abnormally low level ENG E01
system
Electrical
CA153 Charge temperature sensor Abnormally high level ENG E01
system
Electrical
CA154 Charge temperature sensor Abnormally low level ENG E01
system
Electrical
CA155 Charge temperature Abnormally high speed derate ENG E03
system
Electrical
CA187 Sensor power supply 2 Abnormally low level ENG E03
system
Electrical
CA221 Ambient pressure sensor Abnormally high level ENG E01
system
Electrical
CA222 Ambient pressure sensor Abnormally low level ENG E01
system
Electrical
CA227 Sensor power supply 2 Abnormally high level ENG E03
system
Mechanical
CA234 Engine Overspeed ENG E02
system
Electrical
CA238 Ne speed sensor power supply Abnormality ENG E03
system
WA200-6 19

code code record
Electrical
CA271 IMV (IMA) Short circuit ENG E03
system
Electrical
CA272 IMV (IMA) Disconnection ENG E03
system
Electrical
CA322 Injector #1 system Disconnection/Short circuit ENG E03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA342 Engine controller Data mismatching ENG E03
system
Electrical
CA351 Injector drive circuit Abnormality ENG E03
system
Electrical
system
Electrical
system
Electrical
CA428 Water sensor Abnormally high level ENG E01
system
Electrical
CA429 Water sensor Abnormally low level ENG E01
system
Electrical
CA431 Idle validation switch Abnormality ENG E01
system
Electrical
CA432 Idle validation switch Abnormal remedy ENG E03
system
Electrical
CA435 Engine oil pressure switch Abnormality ENG E01
system
Electrical
CA441 Power supply voltage Abnormally low level ENG E03
system
Electrical
CA442 Power supply voltage Abnormally high level ENG E03
system
Electrical
CA449 Common rail pressure Abnormally high pressure 2 ENG E03
system
Electrical
CA451 Common rail pressure sensor Abnormally high level ENG E03
system
Electrical
CA452 Common rail pressure sensor Abnormally low level ENG E03
system
Electrical
CA488 Charge temperature Abnormally high torque derate ENG E03
system
Electrical
CA553 Common rail pressure Abnormally high pressure 1 ENG E03
system
Electrical
CA559 Supply pump Low rail pressure 1 ENG E03
system
Electrical
CA689 Engine Ne speed sensor Abnormality ENG E03
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03
system
Electrical
CA757 Engine controller Loss of all data ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormality ENG E03
system
20 WA200-6

code code record
Electrical
CA1633 KOMNET Abnormality ENG E03
system
Electrical
CA2185 Throttle sensor power supply Abnormally high level ENG E03
system
Electrical
CA2186 Throttle sensor power supply Abnormally low level ENG E03
system
Electrical
system
Electrical
CA2311 IMV (IMA) solenoid Abnormality ENG E03
system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D160KY Backup lamp/buzzer relay Hot short MON E01
system
Electrical
D192KY ECSS solenoid relay Hot short MON E01
system
Electrical
D1B0KA HST safety relay Disconnection HST E03
system
Electrical
D1B0KB HST safety relay Ground fault HST E01
system
Electrical
D1B0KY HST safety relay Hot short HST E03
system
Electrical
D5ZHL6 IGN C system Ground fault/Disconnection MON E01
system
Electrical
DAF3KK UNSW power supply Ground fault/Disconnection MON E01
system
Electrical
DAFRKR Monitor panel CAN-NET signal Disconnection HST E03
system
Electrical
DAJ0KK HST controller power supply Low voltage HST E03
system
HST controller memory Electrical
DAJ0KT Abnormality HST E01
(EEPROM) system
HST controller main power Electrical
DAJ1L4 Disconnection/Ground fault HST E01
supply line system
DAJ1L6 Hot short HST E01
supply line system
Electrical
DAJ2KK Controller solenoid power supply Low voltage HST E03
system
HST controller load power supply Electrical
holding line system
HST controller load power supply Electrical
DAJ2L4 Ground fault HST E01
holding line system
Electrical
DAJ5KX Sensor 5V power supply Out of input range HST E03
system
(DAJ9KQ) HST controller Disagreement in model selection MON E03 —
Electrical
DAJRKR HST controller CAN-NET Disconnection in signal line MON E03
system
(DAJRMA) HST controller Disagreement in option selection MON E03 —
Electrical
DB2RKR Engine controller CAN-NET Disconnection in signal line HST E03
system
WA200-6 21

code code record
Electrical
DD1NL4 Fan auto reverse switch signal Abnormality HST E01
system
Electrical
DD1NLD Fan reverse switch signal Abnormality HST E01
system
Electrical
DDB6KA Parking brake reminder signal Disconnection/Hot short HST E01
system
Electrical
DDB6KB Parking brake indicator signal Ground fault HST E01
system
Parking brake indicator signal or Electrical
DDB6KZ Trouble MON E03
parking brake reminder signal system
Electrical
DDB6L0 Parking brake reminder signal Ground fault HST E01
system
Electrical
DDB6L4 Parking brake indicator signal Disconnection/Hot short HST E03
system
Electrical
DDD7KX Travel speed control dial Disconnection/Ground fault HST E01
system
Electrical
DDD7KY Travel speed control dial Hot short HST E01
system
Emergency steering operation Electrical
DDE5MA Disconnection MON E01
switch system
Electrical
DDK6KA FNR lever Disconnection/Ground fault HST E03
system
Electrical
DDK6KY FNR lever Hot short HST E03
system
Low oil pressure (Operation of Mechanical
DDS5L6 Steering MON E03
emergency steering) system
Travel speed range selector Electrical
DF10KA Disconnection/Ground fault HST E01
switch system
DF10KB Hot short HST E01
switch system
Electrical
DGH1KX HST oil temperature sensor Ground fault MON E01
system
Electrical
DGR2KB Brake oil temperature sensor Ground fault MON E01
system
Electrical
DGR2KZ Brake oil temperature sensor Disconnection/Hot short MON E01
system
Electrical
DHH1KX HST oil pressure sensor Disconnection/Ground fault HST E03
system
Electrical
DHH1KY HST oil pressure sensor Hot short HST E03
system
Electrical
DHTCL6 HST filter clogging sensor Functional defect MON E01
system
Electrical
DJF1KA Fuel level sensor Disconnection/Hot short MON E01
system
Electrical
DLT3KX Travel speed sensor B Abnormality HST E03
system
Electrical
DLT4KX Travel speed sensor A Abnormality HST E03
system
Electrical
DLT4LC Travel speed sensor A & B Abnormality HST E03
system
Electrical
DV00KY Alarm buzzer Hot short MON E01
system
Electrical
DW26KA Motor 2 solenoid Disconnection/Ground fault HST E01
system
22 WA200-6

code code record
Electrical
DW26KY Motor 2 solenoid Hot short HST E01
system
Electrical
DW7BKY Fan reverse solenoid circuit Hot short HST E01
system
Electrical
DW7BKZ Fan reverse solenoid circuit Disconnection/Ground fault HST E01
system
Electrical
DX16KA Fan EPC solenoid Disconnection HST E01
system
Electrical
DX16KB Fan EPC solenoid Ground fault HST E01
system
Electrical
DX16KY Fan EPC solenoid Hot short HST E01
system
Electrical
DX19KA Motor 1 solenoid Disconnection HST E03
system
Electrical
DX19KB Motor 1 solenoid Ground fault HST E03
system
Electrical
DX19KY Motor 1 solenoid Hot short HST E03
system
Electrical
DX20KA Clutch solenoid Disconnection HST E03
system
Electrical
DX20KB Clutch solenoid Ground fault HST E03
system
Electrical
DX20KY Clutch solenoid Hot short HST E03
system
Electrical
DXH7KB Reverse solenoid Ground fault HST E03
system
Electrical
DXH7KZ Reverse solenoid Disconnection/Hot short HST E03
system
Electrical
DXH8KB Forward solenoid Ground fault HST E03
system
Electrical
DXH8KZ Forward solenoid Disconnection/Hot short HST E03
system
Mechanical
J141N1 Steering pump Overrun alarm HST E02
system
Mechanical
M100N1 HST pump Overrun alarm HST E02
system
Mechanical
M400N1 Motor 1 Overrun alarm HST E02
system
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what in displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipment is also included in table.
WA200-6 23
4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] HST: HST controller system
(for each controller) [3] ENGINE: Engine controller system
q 2 items simultaneous display [4] 2 ITEMS: 2 items display
(code input)
4-1. Selecting the menu
Select REAL-TIME MONITORING from the
menu screen of Service mode.
4-4. Setting the 1 item individual monitoring

1) Select the target controller system of mon-
itoring from the sub menu screen.
4-2. Displaying sub menu

Press [U] switch while the menu is selected to
display the sub menu initial screen.
2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.
24 WA200-6
3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
4) Display data for 1 item individual monitor- value.
ing a The cursor moves to the 2nd position.
The 1 item individual monitoring screen 3] Set the value in the same order and
displays the following information. then press [U] switch.
A: Item display a When you have entered a wrong
B: Monitoring codes (5 digits) value to a position except the highest-
1: Monitoring data order digit, the cursor can move to the
(including the unit used) highest-order digit using [t] switch
a See the “Real-time monitoring code and repeat the procedure from the
list” for details. first. In this case, values that had
been entered remain as they are until
modified. When the cursor is at the
highest-order digit, it can move to the
higher layer using [t] switch.
WA200-6 25
3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing.Pressing [U]
switch again restores the active state.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the “Real-time monitoring code list”
for details.
26 WA200-6
WA200-6 27
Real-time monitoring codes table

a Use this page in next page and a spread.
MONITOR PANEL [Machine monitor system]
Monitoring item Displayed item Data display range

No. Monitoring code
(*1) (*2) (*3)
1 20200 Monitor software No. VERSION Alphanumerals
2 20221 Application version No. VERSION (APP) Numerals
3 20222 Data version No. VERSION (DATA) Numerals
4 01001 Engine speed ENG SPEED 0 – 4000
5 40012 Travel speed SPEED 0.0 – 50.0
6 04202 Fuel level FUEL SENSOR 0 – 100
7 04200 Fuel level FUEL SENSOR 0.00 – 5.00
8 04103 Coolant temperature COOLANT TEMP –40 – 210
9 04408 HST oil temperature HST OIL TEMP 24 – 131
10 04409 HST oil temperature HST OIL TEMP 0.00 – 5.00
11 30201 Front brake oil temperature F BRAKE OIL 24 – 131
12 30204 Front brake oil temperature F BRAKE OIL 0.00 – 5.00
13 04302 Charge level ALTERNATOR R 0.0 – 30.0
14 40200 Small lamp voltage SMALL LAMP 0.0 – 30.0
15 06001 Boom angle BOOM ANG -----
16 06003 Boom angle BOOM ANG -----
17 40400 Boom bottom pressure BOOM BTM PRESS -----
18 40402 Boom bottom pressure BOOM BTM PRESS -----
28 WA200-6
a Use this page in front page and spread.
Unit
Contents of display in normal state Remarks
(*4)
Condition
As per software No. 3rd – 10th digits from right of part No. are displayed.
display
Condition
As per software application version No.
display
Condition
As per software data version
display
Low idle : 775 – 850 rpm

rpm Data are obtained from HST controller.
High idle: 2,175 – 2,295 rpm
F1/R1: 4.0 – 7.6 km/h • Shown value is max. speed in each speed range.
F2/R2: 13.0 – 17.9 km/h • Value of F1/R1 is speed when travel speed con-
km/h
F3/R3: 20.0 – 25.9 km/h trol dial is at min. speed position.
F4/R4: 34.5 – 41.1 km/h • Value when tires of size 17.5 are installed.
0 – 100% (Depends on fuel level) %
Gauge FULL (100%, 10 z): 0.31 V

Gauge 1/2 (50%, 30.5 z): 0.84 V When sensor is disconnected, has hot-short: Gauge
Gauge 1/4 (25%, 44.7 z): 1.15 V V EMPTY
Caution (63.0 z): 1.48 V When sensor has ground fault: Gauge FULL
Gauge EMPTY (0%, 85 z): 1.82 V
Engine coolant temperature: Max. 102°C

Depends on machine condition (°C) °C
Data are obtained from engine controller.
Depends on machine condition (°C) °C Overheat: 105°C
Gauge enters red range(105°C): 2.07 V When sensor is disconnected has hot-short: Gauge MIN
V
(80°C): 2.91 V When sensor has ground fault: Gauge MAX
Depends on machine condition (°C) °C
(120°C): 1.62 V
V
1(80°C): 2.91 V
Depends on machine condition (0.0 – 30 V) V
Depends on machine condition (0.0 – 30 V) V
----- deg (°)
----- V
a No use these items.
----- MPa
----- V
WA200-6 29
Monitoring item Displayed item Data display range

No. Monitoring code
(*1) (*2) (*3)
19 40500 Boom head pressure BOOM HEAD PRES -----
20 40501 Boom head pressure BOOM HEAD PRES -----
21 40600 Calibration pressure CAL PRESS -----
22 40800 Weight calculated by load meter MES LOAD -----
23 30802 Rotary switch setting condition SW1, SW2, SW3 F, F, F
24 30904 DIP switch setting condition SW5-1, SW5-2 ON/OFF, ON/OFF
28 40900 Input signal D_IN_0-7 D-IN--0------7 See separate table.
37 40925 Output signal D_OUT_0-3 D-OUT-0--3 See separate table.
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number out of the display range is displayed as “-----”.
*4: If a unit is necessary, the SI unit is used.
30 WA200-6
Unit
(*4)
----- MPa
----- V
a No use these items.
----- MPa
----- t
Condition
a Do not move from initial position.
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
WA200-6 31

Monitoring Input/Output
No. Displayed item Contents of ON/OFF switch
code signal
D-IN-0 Headlamp Headlamp lighting = ON (24 V)/OFF (OPEN)
D-IN-1 Cooling fan reverse switch Switch = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting motor operation = ON (24 V)/OFF (OPEN)
D-IN-3 — —
1 40900 D-IN-4 — —
D-IN-5 — —
Multi-coupler solenoid (Machine with
D-IN-6 Multi-coupler solenoid = ON (24 V)/OFF (OPEN)
optional multi-coupler spec.)
D-IN-7 — —
ECSS switch
D-IN-8 ECSS switch = ON (24 V)/OFF (OPEN)
(Machine with optional ECSS spec.)
Cooling fan automatic reverse setting = ON (24 V)/
D-IN-9 Cooling fan automatic reverse switch
OFF (OPEN)
D-IN-10 — —
2 40901 D-IN-11 — —
D-IN-12 Right winker Right winker lighting = ON (GND)/OFF (OPEN)
D-IN-13 Left winker Left winker lighting = ON (GND)/OFF (OPEN)
D-IN-14 U switch Pressing switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 (ECSS cut switch) a No use (Always “OFF”)
D-IN-18 — —
D-IN-19 — —
3 40902
D-IN-20 (Air cleaner clogging) a No use (Always “OFF”)
D-IN-21 (ECSS cut switch [dummy]) a No use (Always “OFF”)
D-IN-22 — —
D-IN-23 — —
D-IN-24 HST filter clogging Clogging detection = ON (GND)/OFF (OPEN)
D-IN-25 — —
D-IN-26 Parking brake Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
4 40903 D-IN-28 Omission of applying parking brake Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-29 (Engine oil level) a No use (Always “OFF”)
Normal emergency steering Low emergency steering pressure = ON (GND)/OFF
D-IN-30
(Machine with optional emergency steering) (OPEN)
D-IN-31 — —
*: “1” is displayed when ON and “0” is displayed when OFF.
32 WA200-6

code signal
D-IN-32 — —
D-IN-33 — —
D-IN-34 High beam (Dimmer switch) High beam = ON (GND)/OFF (OPEN)
Omission of applying parking brake
D-IN-35 Resetting parking brake = ON (GND)/OFF (OPEN)
(dummy)
5 40904
D-IN-36 Parking brake (dummy) Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-37 [>] switch Pressing switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing switch = ON (GND)/OFF (OPEN)
Low steering pressure (Machine with
D-IN-39 Oil pressure reduction = ON (GND)/OFF (OPEN)
optional emergency steering spec.)
D-OUT-0 Alarm buzzer Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1 — —
6 40952 D-OUT-2 Backup alarm/lamp relay Output ON = ON (24 V)/OFF (OPEN)
ECSS solenoid relay
D-OUT-3 Output ON = ON (24 V)/OFF (OPEN)
(Machine with optional ECSS spec.)
*: “1” is displayed when ON and “0” is displayed when OFF.
WA200-6 33
HST [HST controller system]

Monitoring Real-time monitoring item Displayed item Data display range
No.
code (*1) (*2) (*3)
1 20201 Software No. VERSION
2 20223 Application version No. VERSION (APP)
3 20224 Data version No. VERSION (DATA)
5 40978 Output signal D_OUT_0-7 D-OUT-0------7 See separate table.
6 40979 Output signal D_OUT_8-15 D-OUT-8-----15 See separate table.
7 40980 Output signal D_OUT_16-23 D-OUT-16----23 See separate table.
8 41600 Engine mode ENGINE MODE 0/2
9 32600 HST oil pressure HST PRESS 0.0 – 500.0
10 32601 HST oil pressure HST PRESS 0.001 – 5.000
11 80000 Motor 1 output command value MOTOR SOL DIR 0 – 1000
12 8100 Clutch output command value CLUTCH SOL DIR 0 – 1000
13 41400 Fan output command value FAN EPC DIR 0 – 1000
14 93400 Fan reverse switch input FAN REVERSE SW 0/2/1
15 40013 Travel speed SPEED (HST) 0 – 50.00
16 31400 Output shaft speed T/M SPEED : OUT 0 – 32767
17 31404 Output shaft speed T/M SPEED : OUT2 0 – 32767
18 95400 Throttle correction command output THROTTLE MOD –100 – 100
19 44200 Throttle quantity upper limit value output THROT LIMIT UP 0.0 – 100.0
20 44201 Throttle quantity lower limit value output THROT LIMIT LO 0.0 – 100.0
21 43504 Automatic warm-up cancel flag WARM-UP CANCEL 0/1
34 WA200-6

Unit
(*4)
As per software No. Condition display
As per software application version No. Condition display
As per software data version Condition display
Condition display
Condition display
Condition display
Condition display
0 Condition display “0” is always displayed.
Low-pressure relief pressure: 2.4 – 2.7

MPa
High-pressure cutoff pressure: 43.1 – 46.6
Low-pressure relief pressure: 0.660 – 0.680
V
High-pressure cutoff pressure: 3.373 – 3.607
Above 10.5 km/h in 3rd or 4th gear speed: 0 mA
mA
Other than above: 100 – 600 mA (Depends on control)
When clutch is engaged: 670 mA
When clutch is disengaged Above 10.5 km/h in 3rd or mA
4th gear speed): 0 mA
0 – 1000 mA
• Fan rotation direction is being reversed: 800 mA mA
• Fan is rotating in reverse: 0 mA
Switch position, forward: 0
Switch position, automatic reverse: 2 Condition display
Manual reverse switch is being operated: 1
Depends on travel speed. km/h Not used
0 km/h = 0 min-1
10 km/h = 838 min-1 When tires of size 17.5 are installed.
20 km/h = 1676 min-1 min-1 “min-1” is SI unit of rotation speed.
30 km/h = 2514 min-1 (1 min-1 = 1 rpm)
40 km/h = 3352 min-1
0% % “0%” is always displayed.
Ordinary: 100%
%
Forward travel in S mode: 50 – 100%
0 – 20% %
Directional lever in N, stopped: 0 (OFF)

Condition display
Other than above: 1 (ON)
WA200-6 35

Monitoring Real-time monitoring item Displayed item Data display range
No.
code (*1) (*2) (*3)
22 99100 Parking brake switch signal PARKING A/B 11/00/10/01
23 04302 Alternator R voltage signal ALTERNATOR 0.0 – 30.0
24 99200 Travel speed control dial SPEED POT 0.0 – 50.0
25 99201 Travel speed control dial SPEED POT 0.001 – 5.000
26 80200 Traction level setting TRACTION 0 – 100
27 99101 Forward-Reverse selector switch FNR signal MULTI FNR 100/010/001
28 99300 Machine status HST STATUS 0–6
29 99301 Clutch status CLUTCH STATUS 0–4
30 99302 Forward-Reverse recognition TRAVEL F/R F/R
36 WA200-6

Unit
(*4)
Parking brake position (High): 00
(Middle): 10 Condition display
(Low): 11
0 – 30 V V
4.0 – 13.0 km/h (Depends on travel speed control dial position) km/h
0.9 – 4.1 V (Depends on travel speed control dial position) V
Traction level setting (When stopped)

Tire size 17.5 / Tire size 20.5
Display is as shown at left, regardless of
• When traction level A is set: 82% / 88% %
traction control switch position.
• When traction level B is set: 72% / 77%
• When traction level C is set: 62% / 66%
100: F, 010: N, 001: R
Condition display
ON/OFF refers to each bit.
Stopped: 0
Forward travel (Directional lever in F): 1
Reverse travel (Directional lever in R): 2
Forward travel, lever in R: 3 Condition display
Reverse travel, lever in F: 4
Forward travel, lever in N: 5
Reverse travel, lever in N: 6
Clutch condition
• Engaged o Being prepared for disengaging: 0
• Disengaged (During high-speed travel in 3rd, 4th speed range): 1
• Disengaged o Engagement is being modulated
Condition display
(During deceleration in 3, 4th speed range): 2
• Completion of engagement (During low-speed travel in 1st, 2nd
speed range or 3rd, 4th speed range)
• Being disengaged: 4
Forward travel: F Previous condition is displayed while
Condition display
Reverse travel: R machine is stopped
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*4: If a unit is necessary, the SI unit is used.
WA200-6 37

codes signal
D-IN-0 FNR (Directional) lever F (Forward) F (Forward) = ON (24 V)/OFF (OPEN)
D-IN-1 FNR (Directional) lever N (Neutral) N (Neutral) = ON (24 V)/OFF (OPEN)
D-IN-2 FNR (Directional) lever R (Reverse) R (Reverse) = ON (24 V)/OFF (OPEN)
Right FNR (directional) switch selector

D-IN-3 Pressing switch = ON (24 V)/OFF (OPEN)
switch
1 40977
D-IN-4 Traction control switch Pressing switch = ON (GND)/OFF (OPEN)
D-IN-5 — —
D-IN-6 — —
D-IN-7 — —
D-OUT-0 — —
D-OUT-1 — —
D-OUT-2 — —
D-OUT-3 — —
2 40978
D-OUT-4 — —
D-OUT-5 — —
D-OUT-6 — —
D-OUT-7 — —
D-OUT-8 — —
D-OUT-9 — —
D-OUT-10 — —
D-OUT-11 — —
3 40979
D-OUT-12 — —
D-OUT-13 — —
D-OUT-14 VIS Self-holding relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-15 HST safety relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-16 Motor 2 solenoid relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-17 Fan reverse solenoid relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-18 Fan reverse solenoid relay HST pump F solenoid = ON (24 V)/OFF (OPEN)
D-OUT-19 HST pump R solenoid (Reverse) HST pump R solenoid = ON (24 V)/OFF (OPEN)
4 40980
D-OUT-20 — —
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
“1” is displayed when ON and “0” is displayed when OFF.
38 WA200-6
ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit
No. Remarks
code (*1) (*2) (*3) (*4)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
2 03200 Battery voltage POWER SUPPLY 0.0 – 480.0 V
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP –40 – 210 °C
5 04105 Engine coolant temperature sensor voltage COOLANT TEMP 0.00 – 5.00 V
6 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
7 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
8 37400 Atmospheric pressure AMBIENT PRESS –99.9 – 999.9 kPa
9 37402 Atmospheric pressure sensor voltage AMBIENT PRESS 0.00 – 5.00 V
10 18500 Boost temperature CHG TEMP –50 – 200 °C
11 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
12 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
13 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
14 18700 Engine output torque OUTPUT TORQUE –24000 – 24000 Nm
15 36700 Equivalent torque TORQUE RATIO 0 – 100 %
16 31706 Final accelerator position FINAL THROTTLE 0 – 100 %
17 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 1/h
18 18600 Final injection volume command (in weight) INJECT COMMAND 0 – 1000 mg
19 36300 Final injection timing command TFIN INJECT TIMING –180.0 – 180.0 CA
20 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
21 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
Status
22 18300 Idle validation signal IVS 1 ON/OFF
display
Status
23 18301 Idle validation signal IVS 2 ON/OFF
display
24 18900 Engine controller internal temperature ECM IN TEMP –40 – 210 °C
Final common rail pressure command
25 36200 PRESS COMMAND 0 – 400 MPa
PFIN
Status
26 17500 Selection of engine mode POWER MODE 0–4
display
Status
27 18800 WIF sensor stats WATER IN FUEL ON/OFF
display
Incoming value is
displayed as is Status
28 00400 Name of selected model (upper 8 digits) MACHINE ID (H)
(Upper 8 digits of display
16 characters)
Incoming value is
displayed as is Status
29 00401 Name of selected model (lower 8 digits) MACHINE ID (L)
(Lower 8 digits of display
16 characters)
Incoming value is
Status
30 20216 Build version BUILD VER displayed as is
display
(8 characters)
Incoming value is
Status
31 20217 Calibration data version CAL VER displayed as is
display
(8 characters)
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*4: SI units alone are employed whenever a unit is needed.
WA200-6 39
5. Engine reduced-cylinder function (CYLIN- 3) Selecting a cylinder to be reduced

DER CUT-OUT) Using [<] or [>] switch, select a cylinder to
The engine reduced-cylinder function denotes be reduced from No. 1 – No. 4 cylinders
setting the injector of a single cylinder or two or and then settle the selected cylinder using
more cylinders to electrically no injection state [U] switch.
and turns on the operation on reduced-cylinder a The cylinder to be reduced is selectable
condition. When any cylinders of the engine while the engine is run.
were suspected for abnormal output (combus- a Any number of cylinders can be reduced –
tion), this approach is used to single out the a single unit or two or more units.
failed cylinder. q [>] switch: Advances the cursor right-
1) Selecting the menu ward
Display the CYLINDER CUT-OUT screen q [<] switch: Advances the cursor left-
from the menu screen of Service mode. ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

Press [U] switch while the menu i s
selected to display the sub menu.
a As the reduced-cylinder command is

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
40 WA200-6
4) Cancelling a reduced cylinder 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the reduced-cylinder switch is hit, a communication error should
command from the engine controller. The be suspected.
black display will disappear.
a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the instruction screen will appear.
function capable of lubricating the engine a In such case, stop the engine once and
through no injection cranking. When a machine then do the set up again.
has been stored for a long time, this function is
used to lubricate the engine prior to its restart
in order to prevent its wear or damages out of
oil.
The no injection cranking must be set up while
the engine is stopped.
1) Selecting menu
Display the NO INJECTION screen from
menu screen of Service mode.
WA200-6 41
7. Adjustment function (TUNING) 7-1. Adjustment of interval of fan automatic

The machine monitor implements initial setting reverse operation
after disassembly or replacement of the trans- a This function is used to change the inter-
fer, or after replacement or addition of sensor, val of the forward and reverse operations
HST pump, HST motor and EPC valve or con- of the fan when the fan automatic reverse
troller. Through the initial setting, the machine operation is selected.
monitor corrects and adjusts the installation a The interval of the fan automatic reverse
error or manufacturing variations of individual operation is adjustable in the range from
parts. 0.1 h (6 minutes) to 200 h. It must be set
a Adjustment function to at least twice the continuance of the fan
automatic reverse operation, however,
Item Code
No. No.
Adjustment item and cannot be set shorter than twice.
a When the machine is delivered, the inter-
Adjustment of interval of fan auto-
7-1 03 val of fan automatic reverse operation is
matic reverse operation
set to 2.0 h.
Adjustment of continuance of fan a When the machine is delivered, the con-
7-2 04
automatic reverse operation tinuance of the fan automatic reverse
Adjustment of lift arm angle sensor operation is set to 2 minutes.
7-3 05
(upper) (for load meter) (*) 1) On the service mode menu screen, dis-
Adjustment of lift arm angle sensor play the TUNING screen.
7-4 06
(lower) (for load meter) (*)
Adjustment of ECSS operation travel
7-5 07
speed
* This menu is displayed but it is not used.
a The items which prohibit use

The setting of following items (code: 01,
02) are not changed because of prohibi-
tion of use.
2) Hold down the [U] switch for at least 5

seconds to display the next screen.
a Do not use this item.
42 WA200-6
3) With the [<] and [>] switches, select 03: 7-2. Adjustment of continuance of fan automatic
FAN REV PD screen. reverse operation
a This function is used to change the contin-
uance of the reverse operation when the
fan automatic reverse operation is
selected.
a The continuance of the fan automatic
reverse operation is adjustable in the
range from 0.5 minutes to 10 minutes. It
must be set to below 1/2 of the interval of
the fan automatic reverse operation, how-
ever, and cannot be set longer than 1/2.
a When the machine is delivered, the con-
tinuance of fan automatic reverse opera-
tion is set to 2.0 minutes.
a When the machine is delivered, the inter-
4) Press the [U] switch to settle. val of the fan automatic reverse operation
a If the [U] switch is pressed, the screen is set to 2.0 h.
to adjust the interval of fan automatic 1) On the service mode menu screen, dis-
reverse operation is displayed. play the TUNING screen.
5) With the [<] and [>] switches, select an
interval in the range from “0.1” to “200”
(Unit: h).
6) Press the [t] switch to settle the setting.
a The selected interval of fan automatic
reverse operation is not changed to a
value less than twice the continuance
of the fan automatic reverse operation.

WA200-6 43
3) With the [<] and [>] switches, select 04: 7-5. Adjustment of ECSS operation travel speed
FAN REV PD screen. (if equipped)
a This function is used to adjust the ECSS
operation/reset travel speed.
a The initial ECSS operation travel speed is
5 km/h (3.1 MPH).
a The ECSS reset travel speed is the ECSS
operation travel speed minus 1 km/h (0.6
MPH).
Example: q If the ECSS operation travel
speed is 5 km/h (3.1 MPH),
the ECSS reset travel speed
is 4 km/h (2.5 MPH).
q If the ECSS operation travel
speed is 8 km/h (5.0 MPH),
the ECSS reset travel speed
4) Press the [U] switch to settle. is 7 km/h (4.4 MPH).
a If the [U] switch is pressed, the 1) Display the “TUNING” screen from the
screen to adjust the continuance of menu screen of Service mode.
fan automatic reverse operation is
displayed.
5) With the [<] and [>] switches, select a con-
tinuance in the range from “0.5” to “10”
(Unit: minute).
6) Press the [t] switch to settle the setting.
a The selected continuance of fan auto-
matic reverse operation is not
changed to a value longer than 1/2 of
the interval of the fan automatic
reverse operation.

7-3. Adjustment of lift arm angle sensor (upper)

(Load meter specification)
a This item is not used.
7-4. Adjustment of lift arm angle sensor (lower)

(Load meter specification)
a This item is not used.
44 WA200-6
3) Select “07: ECSS SPEED” with [<] or [>] 8. Maintenance monitoring function
switch. The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
4) Press [U] switch to settle.

a If the selection is settled, the ECSS
operation travel speed adjustment
screen appears.
2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
5) To increase the ECSS operation travel 3) Using [<] or [>] switch, select the item for
speed, press [>] switch. which the maintenance interval is to be
a The operation travel speed is changed from the following.
increased 1 km/h (0.6 MPH) by 1
operation of the switch.
a The operation travel speed can be
adjusted to a maximum of 8 km/h (5.0
MPH).
6) To decrease the ECSS operation travel
speed, press [<] switch.
a The operation travel speed is
decreased 1 km/h (0.6 MPH) by 1
operation of the switch.
a The operation travel speed can be
adjusted to a minimum of 5 km/h (3.1
MPH).
7) If the operation travel speed is set to a
desired value, press [t] switch to finish
setting.
WA200-6 45
List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG FILT 500
Fuel pre-filter 41 FUEL P FILT 500
Fuel filter 03 FUEL FILT 1000
Corrosion resistor 06 CORR RES 1000
Transfer oil 25 TRANSF OIL 1000
HST oil filter 26 HST FILT 1000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000
HST drain filter 43 HST DR FILT 2000
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
5) Maintenance interval time change proce-

dure
1] This cursor is located at the highest-
order digit. Pressing [<] or [>] switch
changes the value of this digit in the
range of 0 – 9.
value.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.
46 WA200-6
6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
“Y ES” i s s elec ted and [t] s witc h is
maintenance interval change item screen
is restored.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3) Inter-
val time change screen displays the a If “Timer by item” is enabled, ON will be
“Selection between enabling or disabling displayed in the upper column.
timer by item” screen.
a When “Timer by item” is enabled, the
order of display is ON o OFF.
WA200-6 47
3) Select “YES” or “NO” using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
“Y ES” i s s ele cted and [t] s witc h i s “ YE S” is s elec ted a nd [t] s witc h is
pressed, the information will be deleted. If pressed, the change will be enabled If
“NO” is selected and [t] switch is “NO” is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
v alue – E lapsed time s ince the las t
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
was executed.
2) Using [<] or [>] switch, select the INITIALIZE a Set enable for enable or disable of individ-
screen from the following table. ual items.
8-4. Selection between timer stop for all items and

enable by item
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
48 WA200-6
2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
3) Press [U] switch to display the ALL

ITEMS o OFF screen.
a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select “YES” or “NO” using [<] or [>]
switch.
“ YE S” is s elec ted a nd [t] s witc h is
maintenance interval change item screen
is restored.
4) Press [<] or [>] switch when selecting the to prevent resetting error.
ALL ITEMS o ON.
WA200-6 49
7) As the timer stop for all items is executed: 9. Operating information display function
a The timer function for all items is stopped It is a fuel consumption-related function and
a n d t h e M A I NT E N A NC E M O NI TO R displays the following information.
screen is restored. q Fuel consumption ratio and average fuel
a Setting for individual items is also disabled. consumption
a If cancelled: The operation is cancelled q Cumulative fuel consumption and travel
a n d t h e M A I NT E N A NC E M O NI TO R distance
screen is restored. q Cumulative fuel consumption and elapsed
8) When timer enable for all items is executed: time
a Interval time being set for all items is exe- q Loaded volume and loading frequency
cuted to the set value before disabled (This display is available only when the
i nd e p e nd e n t o f wh e th e r o r n ot i t i s load meter is installed.)
enabled or disabled for a specific item. 1) Selecting menu
a The timer remaining time is reset. (The Display the OPERATION INFO screen
reset frequency remains the same as from the menu screen of Service mode.
before the resetting.)
a The MAINTENANCE MONITOR screen is
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I NT E N A NC E M O NI TO R
screen is restored.
2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
3) Using [<] or [>] switch, select the item to
be displayed from 1] – 4] on the fuel con-
sumption ratio and average fuel consump-
tion screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column displays fuel con-
sumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q Above value is computed from the
fuel consumption ratio and travel dis-
tance (odometer distance).
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
a Calculation is done only for the dura-
tion in which the engine is run.
50 WA200-6
3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the
elapsed time [h] from the last reset-
ting.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.
2] Cumulative fuel consumption and travel
distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
a The lower column displays the travel
distance [km or mile] from the last
resetting.
q The unit km or mile shall be selected
depending on that used on the odom-
eter.
the upper limit. 4) Deleting display data
a Calculation is done only for the dura- a Data on screens 3) – 1] to 3] allow dele-
tion in which the engine is run. tion.
a Select a desired item and then delete it
using [U] switch.
a Use [t] switch when canceling deletion of
data.
WA200-6 51
5) Setting gain correction

a Gain correction denotes the function of
correcting gain of cumulative fuel con-
sumption.
a Gain correction is reflected 3) – 1] to 3].
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.
value.
8] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50 – +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [–] position and the value
remains as it is.
52 WA200-6
10. OPTIONAL SELECT function

a The procedure for setting an option is as follows; Set the option and turn the starting switch OFF. After
the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again, and
the option is effective.
a Before setting an option, check that the machine model has been selected. (Select the machine model
before setting the option.)
Optional device installation setting table
Display in
No. Item Setting at monitor delivery Contents of selection Remarks
English
Select type (size) of tires to be

1 Tire type TIRE TYPE 17.5
installed.
2 Emergency steering EMERG S/T NO ADD If equipped, select “ADD”.
Right FNR (directional)
3 FNR NO ADD If equipped, select “ADD”.
switch
• Keep to “ADD” normally.
• “NO ADD” is selected, ECO
4 ECO lamp operation ECO LAMP ADD
lamp in machine monitor is
kept turned OFF.
If not installed optionally, select
5 ECSS E. C. S. S. ADD
“NO ADD”.
If fan reverse function is not
6 Reverse fan REVERSE FAN ADD
installed, select “NO ADD”.
Select “MECHA”. MECHA: Mechanical
7 Parking brake PKG BRAKE MECHA
(Do not select “ELEC”.) ELEC: Electric
• Keep to “0” normally.
• If number other than “0” is
selected, only travel speed
9 Tire size correction TIRE SIZE 0%
display in machine monitor
increases or decreases
according to selected number.
• Can be changed in only non-
SI specification. For contents km/h: Display in kilometer
11 Travel speed unit SPEED (UNIT) km/h
of change, see “Remarks” col- MPH: Display in mile
umn.
• Can be changed in only non-
SI specification. For contents
of change, see “Remarks” col-
umn.
NO ADD: (*1)
Selection of travel • To change travel speed dis-
ADD: (*2)
12 speed/engine speed dis- RPM OPT NO ADD play to engine speed display
ADD o NO ADD: (*3)
play on main screen in operator mode, select
NO ADD o ADD: (*4)
“ADD”.
Note: Do not select “ADD” in
region where display of travel
speed is obliged by law.
Selection of engine • Keep to “ADD” normally.
ADD: (*5)
speed/travel speed on • If “NO ADD” is selected,
NO ADD: (*6)
13 normal screen of char- RPM/SPEED ADD “Engine speed or travel
ADD o NO ADD: (*7)
acter display or non-dis- speed” are not displayed on
NO ADD o ADD: (*8)
play character display.
Reference: Item Nos. 8 and 10 are missing.
*1: “Selection of speed/engine speed” is not displayed in operator mode.

*2: “Selection of speed/engine speed” is displayed in operator mode (Tachometer can be displayed as main
item).
WA200-6 53
*3: Fixed to speedometer.

*4: Setting at previous ADD or initial setting.
*5: “Travel speed/rpm on character display: Displayed/Not displayed” is displayed in operator mode.
*6: “Travel speed/rpm on character display: Displayed/Not displayed” is not displayed in operator mode.
*7: Not displayed.
*8: Setting at previous ADD or initial setting.
54 WA200-6
1) Display the OPTIONAL SELECT screen 10-1. Option setting/not setting selection
from the menu screen of Service mode. a Among the items included in the list of installed
optional devices and their setting, the option
setting/not setting selection applies to the fol-
lowing items.
a If the options are not selected, the option non-
selection screen (NO ADD) is displayed.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: TIRE TYPE screen will appear.
a If the [t] switch is pressed, the
screen returns to the OPTIONAL
SELECT screen. a If the options are selected, the option elected
screen (ADD) is displayed.
a Be sure to start setting of each option

o n 1 : T IR E T Y P E s c r e e n . A ft e r a [U] switch allows alternately displaying the
changing or settling the option, set option non-selection screen and the option-
other items in order on the next 2: selected screen.
EMERG S/T screen and the following
screens. Reference: Details of the main items are shown
below.
WA200-6 55
10-2. Selection of optional tire type 10-4. Setting tire deflection option
a Select “1: TIRE TYPE” from “Optional device a Select 9: TIRE SIZE from the list of installed
installation setting table”. optional devices and their setting.
Reference: This screen appears first when the a Pressing [U] switch sequentially displays
screen is changed from the “OPTIONAL [@@]% in the following order.
SELECT” screen. a The display progresses from +00 through –10.
a Each time [U] switch is pressed, the tire type Pressing [U] switch at this point returns the
changes from small to large. display to +00.
Selectable size: 15.5, 17.5 (default) and 20.5
a If the tire type is changed, the operation accep- Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
tance tone (peep) sounds. @@ +00 +02 +04 +06 +08 +10 +12
Order No.8 No.9 No.10 No.11 No.12 No.13 No.14

@@ –02 –4 –6 –8 –10 –12 +00
a As the display is switched, the sound (beep)

indicating acceptance of the operation will be
generated.
10-3. Selection of optional parking brake

a "MECHA" (Mechanical: Default) is displayed.
a Do not change this setting.
10-5. Selection of optional travel speed unit

a If the SI unit specification is selected when
delivered, this menu is not displayed. (Unit is
fixed to km/h.)
a Select “11: SPEED UNIT” from “Optional
device installation setting table”.
a Each time [U] switch is pressed, the speed
unit changes.
Selectable item: MPH (default), km/h
a If the unit is changed, the operation accep-
tance tone (peep) sounds.
56 WA200-6
10-6. Storing option selection 11. Machine serial number input function
1) When the option selection was changed, 1) Display the MACHINE No. SET screen
turn off the starting switch once to stop the from the menu screen of Service mode.
controller operation completely. (After turn-
ing off the starting switch, wait for 15 sec-
onds without doing any switch operation.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
2) Press [U] switch to display the MACHINE

No. screen.
3) Enter the serial number according to the
a The cursor is positioned at the high-
est-order digit.
1] Pressing [<] or [>] switch increases or
decreases the value at the cursor
position. Select a desired value using
these switches.
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the imme-
diately preceding screen is restored.
a Pressing [t] switch while entry is taking
place will move the cursor the highest-
order digit. In this case, repeat entry
from the highest-order digit.
a If [t] switch is pressed while the cur-
sor is at the highest-order digit, the
immediately preceding screen will be
restored.
WA200-6 57
12. Machine model select function a Press [t] switch when stopping the model
(MACHINE WA***) selection.
a The setting of the machine model of the a As the operation is stopped, the sound
machine monitor can be changed with the (beep) indicating acceptance of the opera-
machine model select function. tion will be generated, restoring the
a If the machine monitor is initialized, perform MACHINE screen.
the machine model select operation first. 4) With the [U] switch, settle the changed
a If the machine model select operation is machine model and tire size.
performed, the setting of options is reset. a As the selection is settled, the sound
Accordingly, start with the option select (beep) indicating acceptance of the opera-
operation and select all the options. tion will be generated, restoring the
MACHINE screen.
12-1. Implementing the model change a Check that the desired machine model is
1) Display the MACHINE screen from the displayed on the machine model select
menu screen of Service mode. screen.
a The currently selected machine model is
displayed on the lower line. 12-2. Storing model change
1) When the model change was done, turn off
the starting switch once to stop the controller
operation completely. (After turning off the
starting switch, wait for 15 seconds without
doing any switch operation.)
2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
13. Initialize function

This function is used only in the factory. It is,
therefore, not used for a service purpose.
2) Hold down [U] switch for 5 seconds to
display the model selection screen.
14. Item that refers to SERVICE NEWS

Refer to SERVICE NEWS for the following
3) With the [<] and [>] switches, select the items.
machine model. q Setting of Service meter when machine
a Selectable models monitor is exchanged.
q WA100 q Setting of odometer when machine moni-
q WA150 tor is exchanged.
q WA200
q WA250
q WA270
q WA320
a If wrong model and tire are set,
machine does not work correctly.
58 WA200-6
Pm clinic inspection chart 1 WA200-6 Series No. 70001 and up
Machine serial No.

Hours inspection Engine serial No. SAA4D107E-1 #
Work order No. Date of execution Service Meter Serviceman

Year: Month: Day: h
Questions asked to operator, walk around inspection
Ambient temperature
Was there any abnormality before inspection started?
Max. °C
Min. °C
Altitude m
Max. coolant temp. (During operation) Max. HST oil temp. (During operation)
Segment color W G G G G R R Segment color G G G G G R R
1 2 3 4 5 6 7 1 2 3 4 5 6 7
a If the machine is cold, warm it up fully. <>: Reference value

Standard
Service limit Measurement
Item Conditions Unit value for new value results Pass Fail
machine
Low idle 775 – 850 775 – 850
High idle 2,175 – 2,295 2,175 – 2,295
Engine speed HST stall rpm 2,080 – 2,280 1,980 – 2,295
Hydraulic stall 1,970 – 2,170 1,870 – 2,270
Engine
Full stall (HST stall + hydraulic stall) 1,860 – 2,170 1,760 – 2,270
Blow-by kPa Max. 0.98 1.96
pressure At rated output {mmH2O} {Max. 100} {200}
Min. 0.29 0.25
High idle {Min. 3.0} {2.5}
MPa
Oil pressure SAE15W-40
{kg/cm2} Min. 0.10 0.07
Low idle
{Min. 1.0} {0.7}
a Before starting the inspection, check that the machine does not move when the directional lever is placed in position.
k When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel
safety at a speed of more than 10 km/h.
Directional lever: F
Speed selector
High-pressure 44.6 – 46.6 43.1 – 46.6
switch: 2nd
cut-off pressure {455 – 475} {440 – 475}
Traction control
switch: ON
Low-pressure
relief pressure
(work equip- 2.5 – 2.7 2.4 – 2.7
Directional lever: N
ment PPC cir- {25.5 – 27.5} {24.5 – 27.5}
cuit basic
pressure) • Engine:
Full throttle
• Hydraulic Directional lever: N 2.5 – 2.7 2.4 – 2.7
Servo piston Brake: released {25.5 – 27.5} {24.5 – 27.5}
control pres- oil temp.: MPa
HST
sure 45 – 55°C Directional lever: N {kg/cm2} Max. 0.6 Max. 0.6

Brake: pressed {Max. 6} {Max. 6}
Directional lever: For-
ward and reverse
Gear speed selector
Servo piston switch: 1st
actuation pres- 2.5 – 2.7 2.3 – 2.7
Travel speed control
sure {25.5 – 27.5} {23.5 – 27.5}
dial: Min. side
Measure while driv-
ing at full throttle
(Approx. 5 km/h).
Transfer clutch Hydraulic oil Directional lever: F 2.5 – 2.7 2.4 – 2.7
control pres- temp.: Speed selector
{25.5 – 27.5} {24.5 – 27.5}
sure 45 – 55°C switch: 3rd or 4th
WA200-6 59
WA200-6 Series No. 70001 and up

<>: Reference value
Standard
Service limit Measurement
Item Conditions Unit value for new Pass Fail
value results
machine
Steering wheel Engine low idle 3.3 – 4.1 Max. 4.8

sec.
operating time Engine high idle 3.4 – 4.0 2.7 – 4.7
Steering
Lock frame with frame lock bar

Steering relief MPa 19.9 – 21.3 18.6 – 22.6
Engine high idle
pressure {kg/cm2} {203 – 217} {190 – 230}
Front right 0.9 – 1.1 Max. 0.6
Front left 0.9 – 1.1 Max. 0.6
Brake
Lining thick-
Service brake mm
ness Rear right 0.9 – 1.1 Max. 0.6
Rear left 0.9 – 1.1 Max. 0.6
MPa 20.2 – 21.0 18.6 – 22.6
Relief pressure Bucket relief
{kg/cm2} {206 – 214} {190 – 230}
Raising time 5.0 – 6.0 Max. 8.2
Work equipment
Lift arm speed Engine high Lowering time 3.1 – 4.1 Max. 4.7
idle
Dumping time sec. 1.1 – 1.7 Max. 2.5
Bucket speed Tilting-back time 2.0– 2.6 Max. 3.8
(At full stroke)
Engine Bucket cylinder mm/15 Max. 17 Max. 20

Hydraulic drift
stopped Lift cylinder min. Max. 20 Max. 30
Front axle Must be no excessive metal
Axle
Check differential oil visually — particles

Rear axle
MEMO
60 WA200-6
WA200-6 61
SEN03734-00

© 2007 KOMATSU
All Rights Reserved
62
SEN03735-00
WA200-6
WA200-6 70001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 8
WA200-6 1
SEN03735-00 40 Troubleshooting
Failure codes table 1

Failure Action Category of Reference
Troubled part Trouble Controller
code code record document No.
Mechanical
2G40ZG Brake Oil pressure reduction MON E03
system
Mechanical
6091NX HST filter Clogging MON E01
system
Mechanical
989FN1 Travel speed Overrun alarm MON E02
system
Electrical
AB00L6 Alternator R system Hot short MON E01
system
Ground fault/ Troubleshooting
Electrical
AB00MA Alternator R system Disconnection/Low MON E03 by failure code
system
charge level (Display of
Mechanical code), Part 1
B@BAZG Engine Oil pressure reduction ENG E03 SEN03737-00
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@BCZK Engine Low coolant level MON E01
system
Mechanical
B@C6NS Front brake High oil temperature MON E02
system
Mechanical
B@CRNS HST High oil temperature MON E02
system
Electrical
CA111 Engine controller Internal abnormality ENG E03
system
Engine NE, Bkup speed Electrical
CA115 Abnormality ENG E03
sensor system
Electrical
CA122 Charge pressure sensor Abnormally high level ENG E03
system
Electrical
CA123 Charge pressure sensor Abnormally low level ENG E03
system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03
system
Electrical Troubleshooting
CA144 Coolant temperature sensor Abnormally high level ENG E01 by failure code
system
(Display of
Electrical code), Part 2
CA145 Coolant temperature sensor Abnormally low level ENG E01
system SEN03738-00
Electrical
CA153 Charge temperature sensor Abnormally high level ENG E01
system
Electrical
CA154 Charge temperature sensor Abnormally low level ENG E01
system
Abnormally high speed Electrical
CA155 Charge temperature ENG E03
derate system
Electrical
system
Electrical
CA221 Ambient pressure sensor Abnormally high level ENG E01
system
Electrical
CA222 Ambient pressure sensor Abnormally low level ENG E01
system
2 WA200-6

Electrical
system
Mechanical
CA234 Engine Overspeed ENG E02
system
Ne speed sensor power Electrical
CA238 Abnormality ENG E03
supply system
Electrical
CA271 IMV (IMA) Short circuit ENG E03
system
Electrical
CA272 IMV (IMA) Disconnection ENG E03
system
Disconnection/Short Electrical
CA322 Injector #1 system ENG E03
circuit system Troubleshooting
by failure code
CA324 Injector #3 system ENG E03 (Display of
circuit system
code), Part 2
Disconnection/Short Electrical SEN03738-00
circuit system
circuit system
Electrical
CA342 Engine controller Data mismatching ENG E03
system
Electrical
CA351 Injector drive circuit Abnormality ENG E03
system
Electrical
system
Electrical
system
Electrical
CA428 Water sensor Abnormally high level ENG E01
system
Electrical
CA429 Water sensor Abnormally low level ENG E01
system
Electrical
CA431 Idle validation switch Abnormality ENG E01
system
Electrical
CA432 Idle validation switch Abnormal remedy ENG E03
system
Electrical
CA435 Engine oil pressure switch Abnormality ENG E01
system
CA441 Power supply voltage Abnormally low level ENG E03 by failure code
system
(Display of
CA442 Power supply voltage Abnormally high level ENG E03
system SEN03739-00
Abnormally high pressure Electrical
CA449 Common rail pressure ENG E03
2 system
Common rail pressure Electrical
CA451 Abnormally high level ENG E03
sensor system
Common rail pressure Electrical
CA452 Abnormally low level ENG E03
sensor system
Abnormally high torque Electrical
CA488 Charge temperature ENG E03
derate system
Abnormally high pressure Electrical
CA553 Common rail pressure ENG E03
1 system
WA200-6 3

Electrical
system
Electrical
CA689 Engine Ne speed sensor Abnormality ENG E03
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03
system
Electrical
CA757 Engine controller Loss of all data ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormality ENG E03
system
CA1633 KOMNET Abnormality ENG E03 by failure code
system
(Display of
Throttle sensor power Electrical code), Part 3
CA2185 Abnormally high level ENG E03
supply system SEN03739-00
Throttle sensor power Electrical
CA2186 Abnormally low level ENG E03
supply system
Electrical
system
Electrical
CA2311 IMV (IMA) solenoid Abnormality ENG E03
system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D160KY Backup lamp/buzzer relay Hot short MON E01
system
Electrical
D192KY ECSS solenoid relay Hot short MON E01
system
Electrical
D1B0KA HST safety relay Disconnection HST E03
system
Electrical
D1B0KB HST safety relay Ground fault HST E01
system
Electrical
D1B0KY HST safety relay Hot short HST E03
system
Ground fault/ Electrical
D5ZHL6 IGN C system MON E01
Disconnection system Troubleshooting
by failure code
Ground fault/ Electrical
DAF3KK UNSW power supply MON E01 (Display of
Disconnection system
code), Part 4
Monitor panel CAN-NET Electrical SEN03740-00
DAFRKR Disconnection HST E03
signal system
Electrical
DAJ0KK HST controller power supply Low voltage HST E03
system
HST controller memory Electrical
DAJ0KT Abnormality HST E01
(EEPROM) system
HST controller main power Disconnection/Ground Electrical
DAJ1L4 HST E01
supply line fault system
supply line system
Controller solenoid power Electrical
DAJ2KK Low voltage HST E03
supply system
4 WA200-6

HST controller load power Electrical
supply holding line system
HST controller load power Electrical
DAJ2L4 Ground fault HST E01
supply holding line system
DAJ5KX Sensor 5V power supply Out of input range HST E03 by failure code
system
(Display of
Disagreement in model code), Part 4
(DAJ9KQ) HST controller MON E03 —
selection SEN03740-00
Disconnection in signal Electrical
DAJRKR HST controller CAN-NET MON E03
line system
Disagreement in option
(DAJRMA) HST controller MON E03 —
selection
Disconnection in signal Electrical
DB2RKR Engine controller CAN-NET HST E03
line system
Fan auto reverse switch Electrical
DD1NL4 Abnormality HST E01
signal system
Electrical
DD1NLD Fan reverse switch signal Abnormality HST E01
system
Parking brake reminder Electrical
DDB6KA Disconnection/Hot short HST E01
signal system
Parking brake indicator Electrical
DDB6KB Ground fault HST E01
signal system
Parking brake indicator
Electrical
DDB6KZ siginal or parking brake Trouble MON E03
system
reminder signal
Parking brake reminder Electrical Troubleshooting
DDB6L0 Ground fault HST E01 by failure code
signal system
(Display of
Parking brake indicator Electrical code), Part 5
DDB6L4 Disconnection/Hot short HST E03
signal system SEN03741-00
Disconnection/Ground Electrical
DDD7KX Travel speed control dial HST E01
fault system
Electrical
DDD7KY Travel speed control dial Hot short HST E01
system
Emergency steering Electrical
DDE5MA Disconnection MON E01
operation switch system
DDK6KA FNR lever HST E03
fault system
Electrical
DDK6KY FNR lever Hot short HST E03
system
Low oil pressure
Mechanical
DDS5L6 Steering (Operation of emergency MON E03
system
steering)
Travel speed range selector Disconnection/Ground Electrical
DF10KA HST E01
switch fault system
DF10KB Hot short HST E01
switch system Troubleshooting
by failure code
Electrical
DGH1KX HST oil temperature sensor Ground fault MON E01 (Display of
system
code), Part 6
Brake oil temperature Electrical SEN03742-00
DGR2KB Ground fault MON E01
sensor system
Brake oil temperature Electrical
DGR2KZ Disconnection/Hot short MON E01
sensor system
WA200-6 5

DHH1KX HST oil pressure sensor HST E03
fault system
Electrical
DHH1KY HST oil pressure sensor Hot short HST E03
system
Electrical
DHTCL6 HST filter clogging sensor Functional defect MON E01
system
Electrical
DJF1KA Fuel level sensor Disconnection/Hot short MON E01
system
Electrical
DLT3KX Travel speed sensor B Abnormality HST E03
system
DLT4KX Travel speed sensor A Abnormality HST E03 by failure code
system
(Display of
DLT4LC Travel speed sensor A & B Abnormality HST E03
system SEN03742-00
Electrical
DV00KY Alarm buzzer Hot short MON E01
system
DW26KA Motor 2 solenoid HST E01
fault system
Electrical
DW26KY Motor 2 solenoid Hot short HST E01
system
Electrical
DW7BKY Fan reverse solenoid circuit Hot short HST E01
system
DW7BKZ Fan reverse solenoid circuit HST E01
fault system
Electrical
DX16KA Fan EPC solenoid Disconnection HST E01
system
Electrical
DX16KB Fan EPC solenoid Ground fault HST E01
system
Electrical
DX16KY Fan EPC solenoid Hot short HST E01
system Troubleshooting
by failure code
Electrical
DX19KA Motor 1 solenoid Disconnection HST E03 (Display of
system
code), Part 7
Electrical SEN03743-00
DX19KB Motor 1 solenoid Ground fault HST E03
system
Electrical
DX19KY Motor 1 solenoid Hot short HST E03
system
Electrical
DX20KA Clutch solenoid Disconnection HST E03
system
Electrical
DX20KB Clutch solenoid Ground fault HST E03
system
Electrical
DX20KY Clutch solenoid Hot short HST E03
system
DXH7KB Reverse solenoid Ground fault HST E03 by failure code
system
(Display of
DXH7KZ Reverse solenoid Disconnection/Hot short HST E03
system SEN03743-00
Electrical
DXH8KB Forward solenoid Ground fault HST E03
system
Electrical
DXH8KZ Forward solenoid Disconnection/Hot short HST E03
system
6 WA200-6

Mechanical
J141N1 Steering pump Overrun alarm HST E02
system Troubleshooting
by failure code
Mechanical
M100N1 HST pump Overrun alarm HST E02 (Display of
system
code), Part 7
Mechanical SEN03743-00
M400N1 Motor 1 Overrun alarm HST E02
system
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what in displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipment is also included in table.
WA200-6 7
Fuse locations 1
Connection table of fuse box and slow blow fuse
a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box: FS1

Type of power supply (Power source) Fuse No. Fuse capacity Destination of power (*)
1 20A Starting switch B
2 10 A Hazard lamp
3 15 A HST controller
4 30 A Engine controller
Unswitched power supply Machine monitor
(Slow blow fuse [50 A]) 5 10 A Tachograph
Buzzer
Radio
6 10 A Auto-grease
Room lamp
7 10 A Unswitched power supply for optional devices
8 10 A Headlamp (left)
9 10 A Headlamp (right)
10 10 A Turn signal lamp
Stop lamp relay
11 10 A Stop lamp switch
Stop lamp
VIS power supply holding relay
12 15 A
HST controller
Detent active relay
Accessory power supply ECSS switch
(Slow blow fuse [80 A]) Quick coupler
13 10 A Boom kick-out relay
PPC solenoid
Bucket leveler relay
Proximity switch
Front/Rear wiper
14 20 A Wiper timer
Window washer
Radio
15 10 A Auto-grease
Cigarette lighter
*: Optional devices are included.

Devices which are not set may be included.
8 WA200-6
Fuse box: FS2

Type of power supply (Power source) Fuse No. Fuse capacity Destination of power (*)
1 20 A Air conditioner blower
2 5A Air conditioner compressor
Beacon
3 20 A Working lamp (Front: For addition)
Rotary lamp
4 20 A Glass heater
5 10 A Load meter, air cleaner clogging relay
Accessory power supply 6 20 A Key ON power for optional device

(Slow blow fuse [80A]) 7 10 A DC converter
Parking brake
8 10 A
Horn
9 10 A Air suspension seat
10 10 A Small lamp (right)
11 10 A Small lamp (left)
12 10 A Working lamp (front)
13 10 A Working lamp (rear)
Machine monitor (Starting switch ACC signal)
14 10 A Backup lamp
ACC signal (ACC switch) Backup alarm
15 5A Engine controller (Starting switch ACC signal)
*: Optional devices are included.

Devices which are not set may be included.
Location Fuse No.

q Inside of cover (1) at rear of console in cab
WA200-6 9
Slow blow fuse

Type of power supply (Power source) Fuse capacity Destination of power
Fuse box FS1 No.8 – 15
80 A
Accessory power supply (Battery) Fuse box FS2 No.1 – 15
120A Engine intake air heater relay
Unswitched power supply (Battery) 50 A Fuse box FS1 No.1 – 7
Location Arrangement of slow blow fuse

Remove plate (2) on left side of engine compart-
ment and remove covers (3).
10 WA200-6
WA200-6 11
SEN03735-00

© 2007 KOMATSU
All Rights Reserved
12
SEN03736-00
WA200-6
WA200-6 70001 and up
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Testing before troubleshooting........................................................................................................................ 4
Classification and procedures of troubleshooting ........................................................................................... 5
Information contained in troubleshooting table ............................................................................................... 8
Connection table for connector pin numbers ................................................................................................ 10
T- branch box and T- branch adapter table ................................................................................................... 46
WA200-6 1
General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
2 WA200-6
Sequence of events in troubleshooting 1
WA200-6 3
Testing before troubleshooting 1
Item Criteria Remedy
1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel

— Clean or drain
Check fuel filter and fuel pre-filter for clogging
3. Check of fuel filter for clogging — Replace
4. Check of level and type of oil in engine oil pan Between H and L Add oil
Lubricating oil and coolant
Between FULL and

5. Check of coolant level Add coolant
LOW
6. Check of air cleaner for clogging No red Clean or replace
7. Check of level and type of hydraulic oil Between H and L Add oil
8. Check of level and type of HST oil Between H and L Add oil
9. Check of engine oil filter for clogging — Replace
10. Check of hydraulic oil filter for clogging — Replace
11. Check of HST oil filter for clogging — Replace
Retighten or
12. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
13. Check of alternator terminal cables for looseness and Retighten or

—
corrosion replace
14. Check of starting motor terminal cables for looseness and Retighten or
—
corrosion replace
15. Check of operation of instruments — Repair or replace

mechanical equipment
16. Check for abnormal noise and smell — Repair

Hydraulic and
17. Check for oil leakage — Repair
18. Bleeding air — Bleed air
19. Check of effect of brake — Repair or adjust
20. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
21. Check of battery electrolyte level Between U.L and L.L Add or replace
22. Check wires for discoloration, burn, and removal of cover — Replace
Electrical equipment
23. Check for removed wire clamp and drooping wire — Repair
24. Check wiring for wetting with water (Check connectors and Disconnect and dry
—
terminals for wetting with water, in particular) connectors
25. Check of slow-blow fuses and fuses for disconnection and
— Replace
corrosion
26. Check of alternator voltage (with engine at medium speed or After several-minute
Repair or replace
higher) operation: 27.5 – 29.5 V
27. Check of operating sound of battery relay (Starting switch
— Replace
OFF o ON)
4 WA200-6
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.“, and then carry out trouble-
shooting related to that phenomenon in the “E-mode“, “H-mode“, or “S-mode“.
WA200-6 5
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily (Starting performance is poor) S-1
4 Engine does not turn E-1 S-2 a)
5 Engine turns but no exhaust smoke comes out S-2 b)
Engine does not start
Exhaust smoke comes out but engine does not
6 S-2 c)
start (Fuel is injected)
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-4 S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant or fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate normally E-2
Phenomena related to power train
22 The machine does not start H-1
23 The travel speed is slow H-2
24 The traction force is weak H-3
25 Engine stalls when traveling or engine speed drops excessively H-4
26 The gear is not shifted H-5
27 Travel direction selection system does not function E-6
Phenomena related to steering
28 The steering wheel does not turn H-6
29 The steering wheel is heavy H-7
30 Steering wheel shakes or jerks H-8
31 Machine deviates naturally to one side when traveling H-9
Phenomena related to brake
32 The brake does not work or does not work well H-10
33 The brake is not released or is dragged H-11
6 WA200-6
Phenomena related to work equipment

34 The lift arm does not rise or lower H-12
35 The lift arm moves slowly or the lift arm rising force is insufficient H-13
36 When rising, the lift arm comes to move slowly at specific height H-14
The lift arm cylinder cannot hold down the bucket (The bucket rises in
37 H-15
the air)
38 Hydraulic drifts of the lift arm occur often H-16
39 The lift arm wobbles during operation H-17
When the control lever is switched from "HOLD" to "RAISE," the lift
40 H-18
arm falls temporarily
41 The bucket does not tilt back H-19
42 The bucket moves slowly or the tilting-back force is insufficient H-20
43 The bucket comes to operate slowly in the midst of tilting-back H-21
44 The bucket cylinder cannot hold down the bucket H-22
45 Hydraulic drifts of the bucket occur often H-23
The bucket wobbles during travel with load (The work equipment
46 H-24
valve is set to "HOLD")
When the control lever is switched from "HOLD" to "TILT," the bucket
47 H-25
falls temporarily
The control levers of the lift arm and bucket do not move smoothly
48 H-26
and heavy
49 The ECSS does not operate and machine pitches and bounces H-27
Fan revolution is abnormal (Fan sound/vibration is abnormally large
50 H-28
or engine overheats)
51 Defective boom kick-out function and cancellation E-3
52 Defective bucket positioner function and cancellation E-4
53 Defective lift arm FLOATING holding function and cancellation E-5
Others
54 Wiper does not operate E-7
55 Windshield washer does not operate E-8
56 Headlamp, clearance lamp and tail lamp do not light up or go off E-9
57 Working lamp does not light up or go off E-10
58 Turn signal lamp and hazard lamp do not light up or go off E-11
59 Brake lamp does not light or it keeps lighting up E-12
60 Backup lamp does not light or it keeps lighting up E-13
61 Backup alarm does not sound or it keeps sounding E-14
62 Horn does not sound or it keeps sounding E-15
63 Alarm buzzer does not sound or it keeps sounding E-16
64 Air conditioner does not operate or stop E-17
65 The KOMTRAX system does not work properly E-18
WA200-6 7
Information contained in troubleshooting table 1

Action code Failure code
Monitor Trouble Problem that appears on machine
Monitor display
display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine con-
controller troller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3 as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
4 • Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
8 WA200-6
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• “Connector No. and pin No.” from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
WA200-6 9
Connection table for connector pin numbers (Rev. 2007.7)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
10 WA200-6
WA200-6 11
12 WA200-6
WA200-6 13
14 WA200-6
WA200-6 15
16 WA200-6
WA200-6 17
18 WA200-6
WA200-6 19
20 WA200-6
WA200-6 21
22 WA200-6
WA200-6 23
24 WA200-6
WA200-6 25
26 WA200-6
WA200-6 27
28 WA200-6
WA200-6 29
30 WA200-6
WA200-6 31
32 WA200-6
WA200-6 33
34 WA200-6
WA200-6 35
36 WA200-6
WA200-6 37
38 WA200-6
WA200-6 39
40 WA200-6
WA200-6 41
42 WA200-6
WA200-6 43
44 WA200-6
WA200-6 45
T- branch box and T- branch adapter table 1

(Rev. 2007.7)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
46 WA200-6
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
WA200-6 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
48 WA200-6
WA200-6 49
SEN03736-00
WA200-6 (KA SPEC.) Wheel loader

© 2007 KOMATSU
All Rights Reserved
50
SEN03737-00
WA200-6
WA200-6 70001 and up
Troubleshooting by failure code
(Display of code), Part 1
Failure code [2G40ZG] Brake: Oil pressure reduction.................................................................................... 2
Failure code [6091NX] HST filter: Clogging .................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm...................................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short ................................................................................... 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage ......... 8
Failure code [B@BAZG] Engine: Oil pressure reduction .............................................................................. 10
Failure code [B@BCNS] Engine: Overheat ...................................................................................................11
Failure code [B@BCZK] Engine: Low coolant level...................................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature.......................................................................... 14
Failure code [B@CRNS] HST: High oil temperature..................................................................................... 15
WA200-6 1
Failure code [2G40ZG] Brake: Oil pressure reduction

Action code Failure code Brake: Oil pressure reduction
Trouble
E03 2G40ZG (Machine monitor system)
Contents of • While engine was running (for at least 30 seconds), brake oil pressure sensor detected that oil pres-
trouble sure was below 4.4 MPa {45 kg/cm2} (circuit is open).
• Turns central warning lamp and caution buzzer ON.
• Turns brake oil pressure caution lamp ON.
Action of
• Central warning lamp, alarm buzzer and caution lamp operate for a maximum of 30 seconds after the
machine monitor
engine starts, but no failure codes are displayed.
• if cause of failure disappears, system resets itself.
Problem that
appears on • If machine is used as it is, brake may not work.
machine
Related • Input state (ON/OFF) from brake oil pressure sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL – 40902 – D-IN-16).
Causes Standard value in normal state/Remarks on troubleshooting

System is normal.
1 Brake oil pressure reduction
a Carry out troubleshooting for hydraulic and mechanical systems.
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
T12 (male) Oil pressure Resistance
Defective brake oil pressure
2 Min. 5.88 MPa
sensor (Internal defect) Max. 1 z
{60 kg/cm2}
Between (1) – (2)
Max. 3.92 MPa
Min. 1 Mz
{40 kg/cm2}
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
Disconnection in wiring har- without turning starting switch ON.
value in normal
state ness (Disconnection in wiring Wiring harness between T12 (female) (1) – Resis-
3 Max. 1 z
or defective contact in con- L26 (female) (1) tance
nector) Wiring harness between T12 (female) (2) – Resis-
Max. 1 z
ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
L26 Oil pressure Voltage
4 Defective machine monitor Min. 5.88 MPa
Max. 1 V
{60 kg/cm2}
Between (1) – ground
Max. 3.92 MPa
20 – 30 V
{40 kg/cm2}
2 WA200-6
WA200-6 3
Failure code [6091NX] HST filter: Clogging

Action code Failure code HST filter: Clogging
Trouble
E01 6091NX (Machine monitor system)
Contents of • When HST oil temperature was above 50°C, HST oil filter clogging sensor signal circuit was closed
trouble (in contact with GND).
Action of • Turns HST clogging caution lamp ON.
machine monitor • if cause of failure disappears, system resets itself.
Problem that
appears on • If machine is used as it is, foreign matter may enter HST circuit.
machine
Related The input state from the HST oil filter clogging sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL – 40903 – D-IN-24)

System is normal.
1 Clogged HST oil filter
a Check HST oil filter directly.
without turning starting switch ON.
Defective HST oil filter clog- T13 Filter condition Resistance
2
ging sensor (Internal defect)
Between T13 – Not clogged (Normal) Min. 1 Mz
ground Clogged Max. 1 z
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between T13 – L26 (female) Resis-
3 Max. 1 z
or defective contact in con- (5) tance
nector) Wiring harness between HST oil filter clog- Resis-
Max. 1 z
ging sensor body – ground tance
4 Defective machine monitor L26 Filter condition Voltage
Not clogged (Normal) 20 – 30 V
Clogged Max. 1 V
4 WA200-6
Failure code [989FN1] Travel speed: Overrun alarm

Action code Failure code Travel speed: Overrun alarm
Trouble
E02 989FN1 (Machine monitor system)
Contents of • Travel speed exceeded 45 km/h.
trouble • Auto-decelerator does not work at speed higher than 36 km/h (tire size: 17.5) / 40 km/h (tire size: 20.5).
Action of
• Turns central warning lamp and caution buzzer ON.
machine monitor
Problem that
appears on • If machine is used as it is, brake etc. may be damaged.
machine
Related
• If [DW26KA] or [DW26KY] is displayed, carry out troubleshooting for it first.
information

System is normal (when machine is used as it overruns by acceler-
Possible causes ating on sharp downhill road etc.)
1 Overrun
and standard a Check using condition and teach operator correct using method.
value in normal a Check related components for damage.
state • If alarm is turned ON while travel speed is below limit, machine
2 Defective machine monitor monitor may be defective. (Since trouble is in system, trouble-
shooting cannot be carried out.)
WA200-6 5
Failure code [AB00L6] Alternator R system: Hot short

Action code Failure code Alternator R system: Hot short
Trouble
E01 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
Action of
• Turns the charge circuit error caution lamp ON.
machine monitor
Problem that
appears on • After the engine is started, just turning on the starting switch runs the service meter.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
Related
code: HST – 04302 – ALTERNATOR R).
information
• Method of reproducing failure code: Turn the starting switch ON.

troubleshooting.
Defective alternator Alternator Engine Voltage
1
(Internal trouble) Wiring harness Running (Throttle:
27.5 – 29.5 V
between E02 Above 1/2)
(female) (1) – ground Holds in position Max. 1.5 V
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Hot short in wiring harness
2 Wiring harnesses between E02 (female) (1)
state (Contact with 24V circuit)
– L25 (female) (18), – circuit branch end and Voltage Max. 1 V
ground
troubleshooting.
L25 Engine Voltage
3 Defective machine monitor
Running
Between (18) and 27.5 – 29.5 V
(Throttle: Above 1/2)
ground
Holds in position Max. 1.5 V
6 WA200-6
WA200-6 7
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection

/Low charge voltage
Action code Failure code Alternator R system: Ground fault/Disconnection/Low charge voltage
Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
Action of • Turns the charge circuit failure caution lamp ON.
machine monitor • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
• Deterioration of battery or insufficient charging
appears on
• Engine does not start.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
Related
code: HST – 04302 – ALTERNATOR R).
information
• Method of reproducing failure code: Start engine

1 The battery is deteriorated. The battery may be deteriorated. Check it directly.
troubleshooting.
Defective alternator Alternator Engine Voltage
2
(Internal trouble) Wiring harness Running (Throttle:
27.5 – 29.5 V
between E02 Above 1/2)
(female) (1) – ground Holds in position Max. 1.5 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
Possible causes 3
(Disconnection or defective Wiring harnesses between E02 (female) (1) Resis-
and standard Max. 1 z
contact in connector) – L25 (female) (18) tance
value in normal
state a Prepare by turning starting switch OFF and then start engine to
Grounding fault in wiring har- carry out troubleshooting.
4 ness Wiring harness between E02 (female) (1) –
(Contact with ground circuit) L25 (female) (18) – circuit branch end and Resis-
Min. 1 Mz
tance
ground
troubleshooting.
L25 Engine Voltage
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
ground
Holds in position Max. 1.5 V
8 WA200-6
WA200-6 9
Failure code [B@BAZG] Engine: Oil pressure reduction

Action code Failure code Engine: Oil pressure reduction
Trouble
E03 B@BAZG (Engine controller system)
Contents of
• While engine is run, engine oil pressure became lower than operating range.
trouble
Action of • Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that
appears on • Engine output lowers.
machine
Related
information

Low engine oil pressure Engine oil has potentially gone low. Check the pressure and if it is
1
(When the system is normal) below the specified level, locate and eliminate the cause.
Defective engine oil pressure troubleshooting.
2 switch
OIL PRESSURE SWITCH Resistance
(Internal trouble)
Possible causes Between terminals Min. 1 Mz
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring harness without turning starting switch ON.
3
(Contact with GND circuit) Wiring harnesses between EC1 (female) Resis-
Min. 1 Mz
(17) – OIL PRESSURE SWITCH and ground tance
troubleshooting.
4 Defective engine controller
EC1 Resistance
Between (17) and ground Min. 1 Mz
10 WA200-6
Failure code [B@BCNS] Engine: Overheat

Action code Failure code Engine: Overheat
Trouble
E02 B@BCNS (Engine controller system)
Contents of • While engine was running, engine coolant temperature sensor signal circuit detected engine coolant
trouble overheat.
Action of • Limits fuel injection until coolant temperature lowers to operating range.
machine monitor • Turns central warning lamp and caution buzzer ON.
Problem that
appears on • Engine output decreases.
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE – 04104 – COOLANT TEMP (°C))

Engine coolant overheat
1 Engine coolant may be overheating. Remove cause of overheat.
(when system is normal)
Possible causes
and standard If cause 1 is not detected, engine coolant temperature sensor sys-
Defective engine coolant
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
state [CA144] and [CA145].
If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. Carry out troubleshooting for failure codes [CA144] and
[CA145].
WA200-6 11
Failure code [B@BCZK] Engine: Low coolant level

Action code Failure code Engine: Low coolant level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• Radiator coolant level switch signal circuit was opened (disconnected from GND) for 30 seconds.
trouble
Action of
• Turns radiator coolant level caution lamp ON.
machine monitor
Problem that
appears on • If machine is used as it is, engine may overheat.
machine
Related • Operation of radiator coolant level switch can be checked with monitoring function.

System is normal.
Low radiator sub-tank cool-
1 a Radiator sub-tank coolant level may be low. Check and add cool-
ant level
ant, if necessary.
Sub-tank coolant
Defective radiator coolant B05 (male) Resistance
2 level
level switch (Internal defect)
Above low level
Max. 1 z
Between (1) – (2) (Normal)
Possible causes Below low level Min. 1 Mz

and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal Disconnection in wiring har- without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between L27 (female) (10) – Resis-
3 Max. 1 z
or defective contact in con- B05 (female) (1) tance
nector) Wiring harness between B05 (female) (2) – Resis-
Max. 1 z
ground tance
Sub-tank coolant
L27 Voltage
4 Defective machine monitor level
Above low level
Between (10) – Max. 1 V
(Normal)
ground
Below low level 20 – 30 V
12 WA200-6
WA200-6 13
Failure code [B@C6NS] Front brake: High oil temperature

Action code Failure code Front brake: High oil temperature
Trouble
E02 B@C6NS (Machine monitor system)
• Front brake (axle) high oil temperature was detected (Details are as follows).
Contents of
• Oil temperature above 130°C (when travel speed was below 35 km/h) or above 125°C (when travel
trouble
speed was above 35 km/h) was detected for 5 seconds continuously.
Action of • Turns central warning lamp and caution buzzer ON.
machine monitor • Turns brake oil temperature caution lamp ON.
Problem that
appears on • If machine is used as it is, brake may be damaged.
machine
• If temperature above 120°C is detected for 5 seconds continuously, only caution lamp is turned ON
as preliminary warning.
Related
• Brake oil temperature can be checked with monitoring function.
information
(Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C))
(Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V))

System is normal.
Front brake (Axle) high oil
1 a Front brake (Axle) oil may be overheated. Remove cause of over-
temperature
Possible causes heat.
and standard If cause 1 is not detected, brake oil temperature sensor system may
value in normal Defective brake oil tempera-
2 be defective. Carry out troubleshooting for failure codes [DGR2KB]
state ture sensor
and [DGR2KZ].
If causes 1 and 2 are not detected, machine monitor may be defec-
3 Defective machine monitor tive. Carry out troubleshooting for failure codes [DGR2KB] and
[DGR2KZ].
14 WA200-6
Failure code [B@CRNS] HST: High oil temperature

Action code Failure code HST: High oil temperature
Trouble
E02 B@CRNS (Machine monitor system)
Contents of
• HST oil temperature higher than 105°C was detected for 10 seconds continuously.
trouble
Action of • Turns central warning lamp and caution buzzer ON.
machine monitor • Turns HST oil temperature caution lamp ON.
Problem that
appears on • If machine is used as it is, hydraulic system equipments may be damaged.
machine
• HST oil temperature can be checked with monitoring function.
Related
(Monitoring code: MONITO PANEL – 04408 – HST OIL TEMP (°C))
information
(Monitoring code: MONITO PANEL – 04409 – HST OIL TEMP (V))

System is normal.
Possible causes 1 HST high oil temperature
a HST oil may be overheated. Remove cause of overheat.
and standard
value in normal Defective HST oil tempera- If cause 1 is not detected, HST oil temperature sensor system may
2
state ture sensor be defective. Carry out troubleshooting for failure code [DGH1KX].
tive. Carry out troubleshooting for failure code [DGH1KX].
WA200-6 15
SEN03737-00

© 2007 KOMATSU
All Rights Reserved
16
SEN03738-00
WA200-6
WA200-6 70001 and up
Failure code [CA111] Abnormality in engine controller ................................................................................... 3
Failure code [CA115] Engine Ne or Bkup speed sensor error ........................................................................ 4
Failure code [CA122] Charge pressure sensor high error .............................................................................. 6
Failure code [CA123] Charge pressure sensor low error................................................................................ 8
Failure code [CA131] Throttle sensor high error........................................................................................... 10
Failure code [CA132] Throttle sensor low error ............................................................................................ 12
Failure code [CA144] Coolant sensor high error........................................................................................... 14
Failure code [CA145] Coolant sensor low error ............................................................................................ 16
Failure code [CA153] Charge temperature sensor high error....................................................................... 18
Failure code [CA154] Charge temperature sensor low error ........................................................................ 20
Failure code [CA155] Derating of speed by abnormally high charge temperature ....................................... 22
Failure code [CA187] Sensor power supply 2 low error................................................................................ 24
Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 26
Failure code [CA222] Atmospheric sensor low error .................................................................................... 28
WA200-6 1
Failure code [CA227] Sensor power supply 2 high error .............................................................................. 30

Failure code [CA234] Engine overspeed ...................................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error ......................................................................... 32
Failure code [CA271] IMV (IMA) Short circuit ............................................................................................... 33
Failure code [CA272] IMV (IMA) Disconnection............................................................................................ 34
Failure code [CA322] Injector #1 open/short error ........................................................................................ 36
Failure code [CA342] Calibration code inconsistency................................................................................... 44
Failure code [CA351] Injectors drive circuit error .......................................................................................... 46
Failure code [CA352] Sensor power supply 1 low error................................................................................ 48
Failure code [CA386] Sensor power supply 1 high error .............................................................................. 50
2 WA200-6
Failure code [CA111] Abnormality in engine controller 1

Action code Failure code Abnormality in engine controller
Trouble
E03 CA111 (Engine controller system)
Contents of
• Abnormality occurred in memory of engine controller or power supply circuit.
trouble
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on • The engine does not start.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Possible defect in engine controller (Troubleshooting cannot be car-
state ried out.)
WA200-6 3
Failure code [CA115] Engine Ne or Bkup speed sensor error 1

Action code Failure code Engine Ne or Bkup speed sensor error
Trouble
Contents of
• Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.
trouble
Action of
controller
Problem that
• Engine stops
appears on
• The engine does not start.
machine
Related
information

and standard
value in normal Defective connection of sen- Check Ne speed sensor and Bkup speed sensor directly for defec-
1
state sor connector tive connection (wrong connection).
4 WA200-6
WA200-6 5
Failure code [CA122] Charge pressure sensor high error 1

Action code Failure code Charge pressure sensor high error
Trouble
Contents of
• High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of • Fixes charge pressure (boost pressure) and continues operation.
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output drops.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).

Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out trouble-
1
ply 2 system shooting for it first.
Defective boost pressure BOOST PRESS & IMT Voltage
sensor and temperature sen-
2 Between (2) and (4) Voltage 4.75 – 5.25 V
sors [pressure signal system]
(Internal trouble) Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short (Short circuit with and carry out troubleshooting.
3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (44) –
ness BOOST PRESS & IMT (female) (1) and Voltage Max. 1 V
Possible causes ground
and standard
value in normal
state Short circuit in wiring har-
4 ness Wiring harnesses between EC1 (female)
(with another wiring harness) (44) – BOOST PRESS & IMT (female) (1), Resis- Min.
EC1 (female) (47) – BOOST PRESS & IMT tance 100 kz
(female) (4).
Connecting parts among boost pressure sensor/temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
5
connector • Loose connector, broken lock and, broken seal
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
6 Defective engine controller EC1 Voltage
Between (37) and
Power supply 4.75 – 5.25 V
(47)
6 WA200-6
WA200-6 7
Failure code [CA123] Charge pressure sensor low error 1

Action code Failure code Charge pressure sensor low error
Trouble
Contents of
• Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of • Fixes charge pressure (boost pressure) and continues operation.
Problem that
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).

1
Defective boost pressure BOOST PRESS & IMT Voltage
sensor or temperature sen-
2 Between (2) and (4) Power supply 4.75 – 5.25 V
sor [pressure signal circuit]
(Internal trouble) Voltage is measured with wiring harness connected. Accordingly, if
Grounding fault in wiring har- without turning starting switch ON.
3 ness Wiring harness between EC1 (female) (44) –
(Contact with ground circuit) BOOST PRESS & IMT (female) (1) and Resis- Min.
Possible causes tance 100 kz
ground
and standard
value in normal
4 ness Wiring harnesses between EC1 (female)
(with another wiring harness) (44) – BOOST PRESS & IMT (female) (1), Resis- Min.
EC1 (female) (47) – BOOST PRESS & IMT tance 100 kz
(female) (4)
5
connector • Loose connector, broken lock, broken seal
Between (37) and
(47)
8 WA200-6
WA200-6 9
Failure code [CA131] Throttle sensor high error 1

Action code Failure code Throttle sensor high error
Trouble
Contents of
• High voltage was detected in the throttle sensor signal circuit.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem that
appears on • The engine does not reach full throttle.
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
ENGINE, 31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal trouble) When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
3 5V, 24V circuit) in wiring har-
Possible causes Wiring harness between EC2 (female) (9) –
ness Voltage Max. 1 V
and standard PD1 (female) (2) and ground
value in normal
state
Short circuit in wiring har- without turning starting switch ON.
(with another wiring harness) PD1 (female) (2), EC2 (female) (22) – PD1 Resis- Min.
tance 100 kz
(female) (1)
Connecting parts among accelerator pedal, engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
5 • Loose connector, broken lock, broken seal
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 – 5.25 V
(23) (Power supply)
When released 0.50 – 0.80 V
Between (9) and (23)
10 WA200-6
WA200-6 11
Failure code [CA132] Throttle sensor low error 1

Action code Failure code Throttle sensor low error
Trouble
Contents of
• Low voltage was detected in the throttle sensor signal circuit.
trouble
Problem that
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
ENGINE, 31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2186] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal trouble) When released 0.50 – 0.80 V
Between (2) and (3)
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
3
Possible causes (Short circuit with ground cir- Wiring harness between EC2 (female) (9) – Resis- Min.
and standard cuit) PD1 (female) (2) and ground tance 100 kz
value in normal
state
(with another wiring harness) PD1 (female) (2), EC2 (female) (23) – PD1 Resis- Min.
tance 100 kz
(female) (3)
Connecting parts among fuel control dial, engine unit wiring har-
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 – 5.25 V
(23) (Power supply)
12 WA200-6
WA200-6 13
Failure code [CA144] Coolant sensor high error 1

Action code Failure code Coolant sensor high error
Trouble
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature and continues operation.
controller
Problem that
• Exhaust smoke becomes white
appears on
• Overheat prevention function does not function.
machine
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).

COOLANT TEMP
Coolant temperature Resistance
(male)
Defective coolant tempera-
1 ture sensor 0°C 30 – 37 kz
(Internal trouble) 25°C 9.3 – 10.7 kz
Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
ness Wiring harness between EC1 (female) (15) – Resis-
2 Max. 10z
(Disconnection or defective COOLANT TEMP (female) (B) tance
contact in connector) Wiring harness between EC1 (female) (38) – Resis-
Max. 10z
COOLANT TEMP (female) (A) tance
Possible causes
value in normal without turning starting switch ON.
Short circuit in wiring har-
state Wiring harness among all pins between EC1
3 ness
(with another wiring harness) (female) (15) – EC1 (female) Resis- Min.
(With all connectors of wiring harness distance 100 kz
connected)
Connecting parts among coolant temperature sensor, engine wiring
harness, and engine controller are suspected. Inspect them directly.
connector
EC1 (female) Coolant temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) and
50°C 3.2 – 3.8 kz
(38)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
14 WA200-6
WA200-6 15
Failure code [CA145] Coolant sensor low error 1

Action code Failure code Coolant sensor low error
Trouble
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature and continues operation.
controller
Problem that
appears on
• Overheat prevention function does not function.
machine
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).

COOLANT TEMP
Coolant temperature Resistance
(male)
0°C 30 – 37 kz
Defective coolant tempera-
1 ture sensor 25°C 9.3 – 10.7 kz
(Internal trouble) Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Between (B) and
Possible causes All range Min. 100 kz
ground
and standard
value in normal Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
2
(Short circuit with ground cir- Wiring harness between EC1 (female) (15) – Resis- Min.
cuit) COOLANT TEMP (female) (B) and ground tance 100 kz
3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) – EC1 (female) (With all con- Resis- Min.
tance 100 kz
nectors of wiring harness disconnected)
Connecting parts among coolant temperature sensor, engine wiring
connector
16 WA200-6

EC1 (male) Coolant temperature Resistance
Possible causes 0°C 30 – 37 kz
and standard
25°C 9.3 – 10.7 kz
value in normal 5 Defective engine controller Between (15) and
state 50°C 3.2 – 3.8 kz
(38)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Between (15) and
All range Min. 100 kz
ground
WA200-6 17
Failure code [CA153] Charge temperature sensor high error 1

Action code Failure code Charge temperature sensor high error
Trouble
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).

BOOST PRESS &
Defective [temperature sig- Charge temperature Resistance
IMT (male)
nal circuit] of boost pressure
1 0°C 29 – 36 kz
sensor, temperature sensor
(Internal trouble) 25°C 9 – 11 kz
Between (3) and (4)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
2 Max. 10z
(Disconnection or defective BOOST PRESS & IMT (female) (3) tance
Max. 10z
BOOST PRESS & IMT (female) (4) tance
Possible causes
value in normal Short circuit in wiring har- without turning starting switch ON.
state 3 ness Wiring harness among all pins between EC1
tance 100 kz
4
EC1 (female) Charge temperature Resistance
5 Defective engine controller 0°C 29 – 36 kz
Between (23) and 25°C 9 – 11 kz
(47) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z
18 WA200-6
WA200-6 19
Failure code [CA154] Charge temperature sensor low error 1

Action code Failure code Charge temperature sensor low error
Trouble
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature and continues operation.
controller
Problem that
appears on
• Boost temperature-based engine protection function does not function.
machine
Related
information

BOOST PRESS &
Charge temperature Resistance
IMT (male)
Defective [temperature sig-
nal circuit] of boost pressure 0°C 29 – 36 kz
1
sensor, temperature sensor 25°C 9 – 11 kz
(Internal trouble) Between (2) and (1)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (2) and
ground
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Ground fault in wiring har- without turning starting switch ON.
value in normal ness
2
state (Short circuit with ground cir- Wiring harness between EC1 (female) (23) – Resis- Min.
cuit) BOOST PRESS & IMT (female) (3) and
tance 100 kz
ground
tance 100 kz
4
20 WA200-6

EC1 (female) Charge temperature Resistance
Possible causes
and standard 0°C 29 – 36 kz
value in normal 5 Defective engine controller Between (23) and 25°C 9 – 11 kz
state (47) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (23) and
ground
WA200-6 21
Failure code [CA155] Derating of speed by abnormally high charge

temperature 1
Action code Failure code Derating of speed by abnormally high charge temperature
Trouble
Contents of
• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Action of • Limits output and continues operation.
Problem that
• Engine output drops.
appears on
• Engine stops
machine
Related
information

Cooling performance deterioration of the after cooler is suspected.
Inspect the following points directly.
Drop in cooling performance
Possible causes 1 • Malfunction of hydraulic drive fan
of aftercooler
and standard • Lack of cooling air
value in normal • Clogged aftercooler fin
state Abnormally high tempera-
2 Inspect related parts directly.
ture at turbocharger outlet
If causes 1 – 2 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
22 WA200-6
WA200-6 23
Failure code [CA187] Sensor power supply 2 low error 1

Action code Failure code Sensor power supply 2 low error
Trouble
Contents of
• Low voltage is detected in sensor power supply 2 circuit.
trouble
• Fixes boost pressure and continues operation.
Action of • Fixes charge temperature and continues operation.
controller • Limits output and continues operation.
Problem that
machine
Related
information

a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Disconnect devices at Boost pressure, BOOST PRESS &
right in order. If mark temperature sensor IMT
Defective sensor or wiring E of failure code dis- Common rail
1 appears after repro- FUEL RAIL PRESS
harness pressure sensor
duction operation is
Possible causes Bkup sensor CAM SENSOR
conducted, that
and standard
device or wiring har-
value in normal Engine wiring
ness has a defect in EC1
state harness
it.
Connecting parts among each sensor, engine wiring harness, and
engine controller are suspected. Inspect them directly.
connector
24 WA200-6
WA200-6 25
Failure code [CA221] Atmospheric pressure sensor high error 1

Action code Failure code Ambient pressure sensor high error
Trouble
Contents of
• High voltage is detected in atmospheric pressure sensor
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
Problem that
• Engine does not start easily.
appears on
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).

1
AMBAIR PRESSURE Voltage
Defective atmospheric pres-
sure sensor (Internal trouble)
Voltage is measured with wiring harness connected. Accordingly, if
3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (3) –
ness AMBAIR PRESSURE (female) (3) and Voltage Max. 1 V
Possible causes ground
and standard
value in normal
(with another wiring harness) AMBAIR PRESSURE (female) (3), EC1 Resis- Min.
(female) (33) – AMBAIR PRESSURE tance 100 kz
(female) (1)
Connecting parts among atmospheric pressure sensor, engine wir-
ing harness, and engine controller are suspected. Inspect them
Defective wiring harness directly.
5
Between (33) and
(38)
26 WA200-6
WA200-6 27
Failure code [CA222] Atmospheric sensor low error 1

Action code Failure code Atmospheric sensor low error
Trouble
Contents of
• Low voltage is detected in atmospheric pressure sensor
trouble
Action of
• Fixes atmospheric pressure and continues operation.
controller
Problem that
• Engine does not start easily.
appears on
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).

1
AMBAIR PRESSURE Voltage
Defective atmospheric pres-
sure sensor (Internal trouble)
Ground fault in wiring har- without turning starting switch ON.
ness
3
cuit) AMBAIR PRESSURE (female) (3) and
Possible causes tance 100 kz
ground
and standard
value in normal
(with another wiring harness) AMBAIR PRESSURE (female) (3), EC1 Resis- Min.
(female) (38) – AMBAIR PRESSURE tance 100 kz
(female) (2)
5
Between (33) and
(38)
28 WA200-6
WA200-6 29
Failure code [CA227] Sensor power supply 2 high error 1

Action code Failure code Sensor power supply 2 high error
Trouble
Contents of
• High voltage is detected in sensor power supply 2 circuit.
trouble
• Fixes boost pressure and continues operation.
Action of • Fixes charge temperature and continues operation.
controller • Limits output and continues operation.
Problem that
machine
Related
information

Possible causes engine controller are suspected. Inspect them directly.
and standard 1 • Loose connector, broken lock, broken seal
connector
value in normal • Corrosive, bent, broken, forced-in, or extended pin
state • Humidity in connector, entry of dirt or dust, poor insulation
If cause 1 is not detected, engine controller may be defective.
30 WA200-6
Failure code [CA234] Engine overspeed 1

Action code Failure code Engine Overspeed
Trouble
Contents of
• Engine speed is above upper control limit.
trouble
Action of • Stops injection of injector until engine speed drops to normal level.
Problem that
appears on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by monitoring function (Code: ENGINE, 01001, ENG SPEED).
information • Method of reproducing failure code: Start engine and running at high idle.

Possible causes 1 Use of improper fuel Check fuel used directly.
and standard 2 Improper way of use Way of use may be improper. Teach proper way of use to operator.
value in normal
If causes 1 and 2 are not detected, engine controller may be defec-
state
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
WA200-6 31
Failure code [CA238] Ne speed sensor power supply error 1

Action code Failure code Ne speed sensor supply power error
Trouble
Contents of
• Low voltage is detected in engine Ne speed sensor power supply circuit.
trouble
Action of • Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that
• Starting performance is poor
appears on
• There is hunting from engine.
machine
Related
information

Disconnect devices at
right in order. If failure Ne speed sensor CRANK SENSOR
Defective sensor or wiring code disappears after
1
Possible causes harness reproduction opera-
and standard tion is conducted, that
value in normal device or wiring har- Engine wiring
state ness has a defect in EC1
harness
it.
connector
32 WA200-6
Failure code [CA271] IMV (IMA) Short circuit 1

Action code Failure code IMV (IMA) Short circuit
Trouble
Contents of
• There is short circuit in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that • Engine speed does not rise from low idle.
machine • Common rail fuel pressure is above command value.
Related
information

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) and ground Min. 100 kz
ness
2
cuit) CP3 PUMP REGULATOR (female) (1) and
tance 100 kz
ground
and standard Short circuit in wiring har- without turning starting switch ON.
value in normal 3 ness Wiring harness among all pins between EC1
state (with another wiring harness) (female) (2) – EC1 (female) (With all connec- Resis- Min.
tance 100 kz
tors of wiring harness disconnected)
Connecting parts among supply pump actuator, engine wiring har-
connector
EC1 (female) Resistance
WA200-6 33
Failure code [CA272] IMV (IMA) Disconnection 1

Action code Failure code IMV (IMA) Disconnection
Trouble
Contents of
• There is disconnection in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that
• Engine speed runs, but in unstable condition.
appears on
• Common rail fuel pressure is above command value.
machine
Related
information

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) and (2) Max. 5 z
2 Max. 10 z
(Disconnection or defective CP3 PUMP REGULATOR (female) (1) tance
Max. 10 z
CP3 PUMP REGULATOR (female) (2) tance
Possible causes Hot short (Short circuit with
3
and standard 24V circuit) in wiring harness Wiring harness between EC1 (female) (2) –
CP3 PUMP REGULATOR (female) (1) and Voltage Max. 3 V
value in normal ground
state
(with another wiring harness) (female) (2) – EC1 (female) (With all connec- Resis- Min.
tance 100 kz
tors of wiring harness disconnected)
connector
34 WA200-6
WA200-6 35
Failure code [CA322] Injector #1 open/short error 1

Action code Failure code Injector #1 open/short error
Trouble
Contents of
• There is disconnection or short circuit in drive circuit of injector No. 1.
trouble
Action of
controller
Problem that
• There is irregular combustion or hunting.
appears on
machine
Related
information

1 Defective injector No. 1 INJ CYL 1 Resistance
2 Max. 2 z
(Disconnection or defective INJ CYL 1 (1) tance
Max. 2 z
INJ CYL 1 (2) tance
3 ness
(Contact with ground circuit) Wiring harness between EC1 (female) (45) – Resis-
Max. 2 z
INJ CYL 1 (1) and ground tance
and standard without turning starting switch ON.
value in normal
Short circuit in wiring har- Resis- Min.
(female) (45) – EC1 (female) (With all con-
4 ness tance 100 kz
(with another wiring harness)
Wiring harness among all pins between EC1
Resis- Min.
tance 100 kz
Connecting parts among injector No. 1, engine wiring harness, and
connector
Defective other cylinder If other failure codes are indicated simultaneously, carry out trouble-
6
injector or harness shooting for them.
7 Defective engine controller EC1 (female) Resistance
36 WA200-6
WA200-6 37

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 3 (1) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
38 WA200-6
WA200-6 39

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 2 (2) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
40 WA200-6
WA200-6 41

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 4 (2) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
42 WA200-6
WA200-6 43
Failure code [CA342] Calibration code inconsistency 1

Action code Failure code Calibration code inconsistency
Trouble
Contents of
• Matching error occurred in engine controller data.
trouble
Action of
controller
Problem that
• Continues the normal operation.
appears on
• Engine stops or does not start.
machine
Related
information

and standard 1 Defect in related system If another code is displayed, carry out troubleshooting for it.
value in normal Possible defect in engine controller (Troubleshooting cannot be car-
state 2 Defective engine controller
ried out.)
44 WA200-6
WA200-6 45
Failure code [CA351] Injectors drive circuit error 1

Action code Failure code Injectors drive circuit error
Trouble
Contents of
• Abnormality occurred in injector drive power supply circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
• Exhaust smoke is black.
Problem that
• There is irregular combustion.
appears on
machine
Related
information

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Defective fuse No. 4 of fuse
2 If the fuse is broken, the circuit probably has a grounding fault, etc.
box FS1
L107 (Male) Resistance
Defective engine control cut-
Between (1) and (2) 200 – 400 z
out relay 1 (L107)
3 a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection or
short circuit) and carry out troubleshooting.
When engine control cut-out relay 1 (L107) is replaced with a relay
of the same type, if the condition becomes normal, the engine con-
trol cut-out relay 1 is defective.
Possible causes
and standard L108 (male) Resistance
Defective engine control cut-
value in normal Between (1) and (2) 200 – 400 z
out relay 2 (L108)
state 4 a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection or
short circuit) and carry out troubleshooting.
When engine control cut-out relay 2 (L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine con-
trol cut-out relay 2 is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis- Max.
ness box FS1 – L107, L108 (female) (3) tance 0.5 z
5
(Disconnection or defective Wiring harness between L107 (female) (5), Resis- Max.
contact in connector) L108 (female) (5) – EC3 (female) (3), (4) tance 0.5 z
Wiring harness between EC3 (female) (1), Resis- Max.
(2) – ground tance 10 z
6 Defective engine controller (Since trouble is in the system, troubleshooting cannot be carried
out.)
46 WA200-6
WA200-6 47
Failure code [CA352] Sensor power supply 1 low error 1

Action code Failure code Sensor power supply 1 low error
Trouble
Contents of
• Low voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of • Fixes atmospheric pressure and continues operation.
Problem that
• Starting performance is poor.
appears on
machine
Related
information

Disconnect devices at Atmospheric pres-
AMBAIR PRESSURE
right in order. If failure sure sensor
Defective sensor or wiring code disappears after
1
harness reproduction opera-
tion is conducted, that Engine wiring
Possible causes EC1
device or wiring har- harness
and standard
ness has a defect in
value in normal
it.
state
2
48 WA200-6
WA200-6 49
Failure code [CA386] Sensor power supply 1 high error 1

Action code Failure code Sensor power supply 1 high error
Trouble
Contents of
• High voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of • Fixes atmospheric pressure and continues operation.
Problem that
• Starting performance is poor.
appears on
machine
Related
information

Possible causes
and standard 1
value in normal
state
If cause 1 is not detected, engine controller may be defective.
50 WA200-6
WA200-6 51
SEN03738-00

© 2007 KOMATSU
All Rights Reserved
52
SEN03739-00
WA200-6
WA200-6 70001 and up
Failure code [CA428] Abnormally high level in water sensor.......................................................................... 4
Failure code [CA429] Abnormally low level in water sensor ........................................................................... 6
Failure code [CA431] Idle validation switch error............................................................................................ 8
Failure code [CA432] Idle validation action error .......................................................................................... 12
Failure code [CA435] Engine oil pressure switch error................................................................................. 16
Failure code [CA441] Battery voltage low error ............................................................................................ 17
Failure code [CA442] Battery voltage high error ........................................................................................... 20
Failure code [CA449] Common rail pressure high error 2 ............................................................................ 22
Failure code [CA451] Common rail pressure sensor high error.................................................................... 24
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature....................................... 28
Failure code [CA553] Common rail pressure high error 1 ............................................................................ 29
Failure code [CA559] Supply pump pressure very low error ........................................................................ 30
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32
WA200-6 1
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34
Failure code [CA757] All continuous data lost error ...................................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46
Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50
Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52
Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54
2 WA200-6
WA200-6 3
Failure code [CA428] Abnormally high level in water sensor 1

Action code Failure code Abnormally high level in water sensor
Trouble
Contents of
• High voltage occurred in fuel water sensor
trouble
Action of
• None in particular.
controller
Problem that
appears on • Water separator monitor does not indicate normally.
machine
Related
information

1 Defective fuel water sensor
E42 (female) Resistance
2 Max. 10 z
(Disconnection or defective E42 (male) (1) tance
Max. 10 z
E42 (male) (2) tance
Possible causes
value in normal Short circuit in wiring har- without turning starting switch ON.
state 3 ness Wiring harness among all pins between EC1
tance 100 kz
Connecting parts among fuel water sensor, engine wiring harness,
and engine controller are suspected. Inspect them directly.
connector
4 WA200-6
WA200-6 5
Failure code [CA429] Abnormally low level in water sensor 1

Action code Failure code Abnormally low level in water sensor
Trouble
Contents of
• Low voltage occurred in fuel water sensor
trouble
Action of
controller
Problem that
appears on • Water separator monitor does not indicate normally.
machine
Related
information

1 Defective fuel water sensor E42 (female) Resistance
2 ness
(Contact with ground circuit) Wiring harness between EC1 (female) (14) – Resis- Min.
E42 (male) (1) and ground tance 100 kz
state
tance 100 kz
Connecting parts among fuel water sensor, engine wiring harness,
connector
6 WA200-6
WA200-6 7
Failure code [CA431] Idle validation switch error 1

Action code Failure code Idle validation switch error
Trouble
Contents of
• Abnormality occurred in idle validation switch circuit
trouble
Action of
• Operates at position of throttle of throttle sensor.
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: ENGINE, 18300, IVS 1).
Related
information

PD1 Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1
1 See Fig. 1
(Internal trouble) Between (6) and (4) Signal 2
Wiring harness between EC2 (female) (11) – Resis-
Max. 1 z
PD1 (female) (5) tance
Disconnection in wiring har- Wiring harness between EC2 (female) (1) – Resis-
Max. 1 z
ness PD1 (female) (6) tance
Possible causes 2
and standard (Disconnection or defective Wiring harness between EC2 (female) (32) – Resis-
contact in connector) Max. 1 z
value in normal PD1 (female) (4) tance
state Wiring harness between EC2 (female) (21) – Resis-
Max. 1 z
Wiring harness between EC2 (female) (29) – Resis-
Max. 1 z
Resis- Min.
(female) (11) – EC2 (female) (PD1 and 2,
tance 100 kz
too, is disconnected.)
Short circuit in wiring har-
3 ness Resis- Min.
(female) (1) – EC2 (female) (PD1 and 2, too,
(with another wiring harness) tance 100 kz
is disconnected.)
Between EC2 (female) (11) – EC3 (female) Resis- Min.
(3), (4) (PD1 and 2, too, is disconnected.) tance 100 kz
Between EC2 (female) (1) – EC3 (female) Resis- Min.
(3), (4) (PD1 and 2, too, is disconnected.) tance 100 kz
8 WA200-6

Possible causes Connecting parts among accelerator pedal, engine unit wiring har-
and standard ness, and engine controller are suspected. Inspect them directly.
value in normal Defective wiring harness
state connector
EC2 (female) Signal name Voltage
Possible causes 5 Defective engine controller
and standard Between (11) and
Signal 1
value in normal (32) See Fig. 1
state Between (1) and (32) Signal 2
WA200-6 9
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 x
when pedal opened)
10 WA200-6
WA200-6 11
Failure code [CA432] Idle validation action error 1

Action code Failure code Idle validation action error
Trouble
Contents of
• Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
trouble
1. When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor, on
the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to 0%
after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while after
Action of the accelerator pedal is ON.
controller 2. When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on
the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0%
(fix to the low idle).
Problem that
appears on • Engine speed does not rise from low idle.
machine
Related
information
• The input state from throttle position sensor can be checked with the monitoring function
(Code: ENGINE, 31701/31707, THROTTLE POS)

PD1 Signal name Voltage
When 0.50 –
released 0.80 V
Between (2) and (3) APS sig.
When 3.70 –
1 Defective accelerator pedal
pressed 4.00 V
Between (5) and (4) IVS 1
Possible causes See Fig. 1
and standard Between (6) and (4) IVS 2
value in normal Sensor voltage is measured with wiring harness connected. Accord-
state ingly, if voltage is abnormal, check wiring harness and controller for
Disconnection in wiring har- Wiring harness between EC2 (female) (22) – Resis- Max.
ness PD1 (female) (1) tance 10 z
2
(Disconnection or defective Wiring harness between EC2 (female) (9) – Resis- Max.
contact in connector) PD1 (female) (2) tance 10 z
Wiring harness between EC2(female) (21) – Resis- Max.
PD2 (female) (1) tance 10 z
12 WA200-6

Resis- Min.
(female) (22) – EC2 (female) (PD1 and 2,
tance 100 kz
Short circuit in wiring har- too, is disconnected.)
(with another wiring harness) (female) (9) – EC2 (female) (PD1 and 2, too, Resis- Min.
tance 100 kz
is disconnected.)
Wiring harness between EC2 (female) (21) –
Resis- Min.
EC2 (female) (PD1 and 2, too, is discon-
tance 100 kz
Possible causes nected.)
and standard Connecting parts among accelerator pedal, engine unit wiring har-
value in normal ness, and engine controller are suspected. Inspect them directly.
state Defective wiring harness
connector
EC2 (female) Accelelator pedal Voltage
Between (11) and
5 Defective engine controller Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
WA200-6 13
14 WA200-6
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
when pedal opened)
B: Voltage when pedal opened + 0.1 x
when pedal opened)
WA200-6 15
Failure code [CA435] Engine oil pressure switch error 1

Action code Failure code Engine oil pressure switch error
Trouble
Contents of
• Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
controller
Problem that
• Engine oil switch-based engine protection function does not function.
appears on
• Engine oil pressure monitor does not indicate normally.
machine
Related
• Method of reproducing failure code: Starting switch ON or start engine
information

Defective engine oil pressure
1 OIL PRESSURE SWITCH (male) Resistance
switch
Between OIL PRESURE
Max. 10 z
SWITCH (male) and body
2
(Disconnection or defective Wiring harness between EC1 (female) (17) – Resis-
OIL PRESSURE SWITCH (female) tance
state (with another wiring harness) (female) (17) – EC1 (female) (With all con- Resis- Min.
tance 100 kz
Connecting parts among engine oil pressure switch, engine wiring
connector
Between (17) and ground Max. 10 z
16 WA200-6
Failure code [CA441] Battery voltage low error 1

Action code Failure code Battery voltage low error
Trouble
Contents of
• Low voltage (Max. 6 V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
• Engine stops
appears on
machine
Related
information

Loose, corroded battery ter-
1 Inspect battery terminal directly for loose and corrosion.
minal
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (–) OFF Min. 12 V
terminals START Min. 6.2 V
Defective fuse No. 4 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
3
box FS1 (See cause 6.)
Defective engine control cut- Between (1) and (2) 200 – 400 z
4 out relay (L107) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
connection or short circuit) and carry out troubleshooting.
Possible causes When engine control cut-out relay (L107) is replaced with a relay of
and standard the same type, if the condition becomes normal, the engine control
value in normal cut-out relay (L107) is defective.
state
When engine control cut-out relay (L108) is replaced with a relay of
the same type, if the condition becomes normal, the engine control
cut-out relay (L108) is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis-
Max. 10 z
ness box FS1 – L107, L108 (female) (3) tance
6
(Disconnection or defective Wiring harness between L107 (female) (5), Resis-
L108 (female) (5) – EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), Resis-
Max. 10 z
(2) – ground tance
WA200-6 17

Ground fault in wiring har- Wiring harness between fuse No. 4 of fuse
Resis- Min.
7 ness box FS1 – L107, L108 (female) (3) and
tance 100 kz
(Contact with ground circuit) ground
Wiring harness between L107 (female) (5), Resis-
Max. 10z
L108 (female) (5) – EC (3), (4) and ground tance
Wiring harness among pins between EC3
Resis- Min.
(female) (3), (4) – EC3 (female) (1), (2)
tance 100 kz
Short circuit in wiring har- (With battery terminal disconnected)
Possible causes 8 ness Wiring harness among all pins between EC3
(with another wiring harness) (female) (3), (4) – EC2 (female) Resis- Min.
and standard
tance 100 kz
value in normal (With battery terminal disconnected)
Resis- Min.
(female) (1), (2) – EC2 (female)
tance 100 kz
(With battery terminal disconnected)
Connecting parts among fuse No. 4 of fuse box FS1, engine unit
wiring harness, and engine controller are suspected. Inspect them
9
10 Defective engine controller EC3 (female) Starting switch Voltage
Between (3), (4) and ON Min. 24 V
(1), (2) START Min. 12 V
18 WA200-6
WA200-6 19
Failure code [CA442] Battery voltage high error 1

Action code Failure code Battery voltage high error
Trouble
Contents of
• High voltage (min. 36V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

1 Defective battery voltage
Battery Voltage
Between (+) and (–) terminals Less than 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal 2 Defective alternator E02 (male) Engine speed Voltage
state
Between (1) and
Min. medium speed 27.5 – 29.5 V
ground
EC3 (female) Voltage
Between (3), (4) and (1), (2) Less than 32 V
20 WA200-6
WA200-6 21
Failure code [CA449] Common rail pressure high error 2 1

Action code Failure code Common rail pressure high error 2
Trouble
Contents of
• Voltage (2) in common rail circuit is abnormally high.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
Problem that
• Engine sound becomes larger under no load or light load.
appears on
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).

1 Defect in related system • If another code is displayed, carry out troubleshooting for it.
Commingling of air with the low pressure circuit is suspected.
Inspect the circuit directly in the following procedure.
1) Remove the pressure pickup plug (outlet side) of the fuel main fil-
2 Air in low-pressure circuit
ter.
2) Operate the feed pump of the fuel pre-filter.
3) Inspect leakage of fuel and air from the pressure pickup plug.
a For check of pressure in fuel return circuit, see Testing and
Defective fuel return circuit adjusting, “Testing fuel pressure”.
3
device Max. 0.02 MPa
Possible causes Fuel circuit pressure At low idle or cranking
and standard {Max. 0.19 kg/cm2}
value in normal a Prepare with starting switch ON, then carry out troubleshooting
state without turning starting switch OFF.
Defective common rail pres- Monitoring code
4 Monitoring information
sure sensor (Machine monitor)
Code: 36400, Condition when 0 – 0.39 MPa
RAIL PRESS engine stopped {0 – 4 kg/cm2}
For testing of leakage from pressure limiter, see Testing and adjust-
ing, “Testing leakage from pressure limiter and return rate from
5 Defective pressure limiter injector”.
Leakage from pres-
At low idle 0 cc (No leakage)
sure limiter
6 Defective supply pump If causes 1 – 5 are not detected, supply pump may be defective.
22 WA200-6
WA200-6 23
Failure code [CA451] Common rail pressure sensor high error 1

Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• High voltage occurred in common rail pressure sensor.
trouble
Problem that
appears on
• Engine speed or output drops.
machine
Related
information

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
3 5V, 24V circuit) in wiring har-
ness Wiring harness between EC1 (female) (25) –
Voltage Max. 1 V
Possible causes FUEL RAIL PRESS (female) (2) and ground
(with another wiring harness) FUEL RAIL PRESS (female) (2), EC1 Resis- Min.
(female) (37) – FUEL RAIL PRESS (female) tance 100 kz
(3)
Connecting parts among common rail pressure sensor, engine wir-
5
Between (37) and
(47)
24 WA200-6
WA200-6 25
Failure code [CA452] Common rail pressure sensor low error 1

Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• Low voltage occurred in common rail pressure sensor.
trouble
Problem that
appears on
• Engine speed or output drops.
machine
Related
information

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
Ground fault in wiring har- and carry out troubleshooting.
3 ness
Possible causes FUEL RAIL PRESS (female) (2) and ground tance 100 kz
(with another wiring harness) FUEL RAIL PRESS (female) (2), EC1 Resis- Min.
(female) (37) – FUEL RAIL PRESS (female) tance 100 kz
(3)
Connecting parts among common rail pressure sensor, engine wir-
5
Between (37) and
(47)
26 WA200-6
WA200-6 27
Failure code [CA488] Derating of torque by abnormally high charge

temperature 1
Action code Failure code Derating of torque by abnormally high charge temperature
Trouble
Contents of
• Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Problem that
machine
• The input state (boost temperature) from the boost pressure and temperature sensors can be
Related
• The input state (boost temperature sensor voltage) from the boost pressure and temperature sen-
information
sors can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).

Inspect following directly.
Drop in cooling performance • Malfunction of hydraulic drive fan
Possible causes 1
of aftercooler • Insufficient cooling air
and standard • Clogged aftercooler fin
value in normal
state Abnormally high tempera-
2 Inspect related parts directly.
ture at turbocharger outlet
28 WA200-6
Failure code [CA553] Common rail pressure high error 1 1

Action code Failure code Common rail pressure high error 1
Trouble
Contents of
• Voltage (1) in common rail circuit is abnormally high.
trouble
Action of • None in particular.
Problem that
• Engine sound becomes larger under no load or light load.
appears on
machine
Related
information

Possible causes Inspect following directly for connection of ground terminal.

and standard • Ground terminal (battery (-)) of machine main unit.
Defective connection of
value in normal 2 • Ground terminal of engine
ground terminal
state • Ground terminal of engine controller
• Ground terminal of starting motor
Broken O-ring of supply
3 Inspect O-ring directly for breakage.
pump actuator
WA200-6 29
Failure code [CA559] Supply pump pressure very low error 1

Action code Failure code Supply pump pressure very low error
Trouble
Contents of
• No-pressure feed (1) occurred in common rail circuit.
trouble
Action of
controller
Problem that • Engine does not start or starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output drops.
Related
information

Inspect for fuel leakage directly (visual inspection at engine low
1 Fuel leakage to outside
idle).
a For check of pressure in fuel low-pressure circuit, see Testing and
adjusting, “Testing fuel pressure”.
Cranking
0.3 – 1.1 MPa
Defective low-pressure cir- (When starting is not
2 {3.1 – 11.3 kg/cm2}
cuit device Pressure in fuel low- available)
pressure circuit At low idle
0.5 – 1.3 MPa
(When starting is
{5.1 – 13.3 kg/cm2}
available)
For testing of leakage from pressure limiter, see Testing and adjust-
ing, “Testing leakage from pressure limiter and return rate from
3 Defective pressure limiter injector”.
Leakage from pres-
At low idle 0 cc (No leakage)
Possible causes sure limiter
and standard a For testing of return rate from injector, see Testing and adjusting,
value in normal “Testing leakage from pressure limiter and return rate from injec-
state tor”.
Defective injector Cranking
4 (High-pressure piping in (When starting is not Max. 90 cc/min.
head included) Return rate from available)
injector At low idle
(When starting is Max. 180 cc/min.
available)
a For testing of return rate from supply pump, see Testing and
adjusting, Testing leakage-from pressure limiter and return rate
from injector.
Cranking
5 Defective supply pump (When starting is not Max. 140 cc/min.
Return rate from sup- available)
ply pump At low idle
(When starting is Max. 1,000 cc/min.
available)
30 WA200-6
WA200-6 31
Failure code [CA689] Engine Ne speed sensor error 1

Action code Failure code Engine Ne speed sensor error
Trouble
Contents of
• Abnormality occurred in signals from engine Ne speed sensor.
trouble
Problem that • There is hunting from engine.
appears on • Starting performance is poor
machine • Engine output drops.
Related
information

Defective Ne speed sensor If failure code [CA238] is indicated simultaneously, carry out trouble-
1
power supply system shooting for it first.
CRANK SENSOR Voltage
Defective engine Ne speed
sensor
Broken engine Ne speed
3 sensor or defective clear- Inspect engine Ne speed sensor for breakage or clearance.
ance
Broken rotation sensing fly-
4 Inspect it for breakage directly.
wheel
Possible causes
and standard 5
value in normal (Disconnection or defective Wiring harness between EC1 (female) (27) – Resis- Max.
state contact in connector) CRANK SENSOR (female) (3) tance 10 z
6 ness
CRANK SENSOR (female) (3) and ground tance 100 kz
Hot short (Contact with 5V, and carry out troubleshooting.
7
24V circuit) in wiring harness Wiring harness between EC1 (female) (27) –
Voltage Max. 1 V
CRANK SENSOR (female) (3) and ground
CRANK SENSOR (female) (3), EC1 (female)
8 ness tance 100 kz
(16) – CRANK SENSOR (female) (1)
Resis- Min.
CRANK SENSOR (female) (3), EC1 (female)
tance 100 kz
(48) – CRANK SENSOR (female) (2)
32 WA200-6

Connecting parts among engine Ne speed sensor, engine wiring
Possible causes connector
and standard • Humidity in connector, entry of dirt or dust, poor insulation
value in normal
state
Between (16) and
(48)
WA200-6 33
Failure code [CA731] Engine Bkup speed sensor phase error 1

Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
• Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Problem that • Engine does not start or is difficult to start.
appears on • Idle speed is unstable.
machine • Exhaust smoke is black.
Related
information

Broken engine Ne speed
1 Inspect engine Ne speed sensor for breakage directly.
sensor
Broken engine Bkup speed
2 Inspect engine Bkup speed sensor for breakage directly.
sensor
Inspect it for defect or breakage according to the following proce-
dure.
Defective/broken mount of
1) Set No. 1 cylinder to compression top dead center (align stamp-
3 rotation sensing flywheel on
ing mark).
crankshaft side
2) If tip of Ne speed sensor is aligned with center of oblong hole of
rotation sensing flywheel, it is mounted normally.
Possible causes
and standard Inspect it for defect or breakage according to the following proce-
value in normal dure.
state Defective/broken mount of 1) Set No. 1 cylinder to compression top dead center (align stamp-
4 rotation sensing ring on cam- ing mark).
shaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 thread) of rotation sensing ring can be seen
through sensor mounting hole, it is mounted normally.
Defective timing between
5 Inspect crankshaft and camshaft for timing directly.
crankshaft and camshaft
Inspect following directly for connection of ground terminal.
• Ground terminal (battery (-)) of machine main unit.
Defective connection of
6 • Ground terminal of engine
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
34 WA200-6
Failure code [CA757] All continuous data lost error 1

Action code Failure code All continuous data lost error
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that • Engine stops and sometimes cannot be started.
appears on • The monitoring function of the machine monitor (engine controller system) sometimes fail to work
machine normally.
Related
information

Loose, corroded battery ter-
2 Inspect battery terminal directly for loose and corrosion.
minal
with starting switch OFF and START.
3 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) – (–) ter- OFF Min. 12 V
minals START Min. 6.2 V
Defective fuse No. 4 of fuse
4 If the fuse is broken, the circuit probably has a grounding fault, etc.
box FS1
L107 (male) Resistance
Possible causes
and standard When engine control cut-out relay (L107) is replaced with a relay of
value in normal the same type, if the condition becomes normal, the engine control
state cut-out relay (L107) is defective.
When engine control cut-out relay (L108) is replaced with a relay of
the same type, if the condition becomes normal, the engine control
cut-out relay (L108) is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis-
Max. 10z
ness box FS1 – L107, L108 (female) (3) tance
7
(Disconnection or defective Wiring harness between L107 (female) (5), Resis-
contact in connector) Max. 10z
L108 (female) (5) – EC3 (female) (3), (4) tance
Max. 10z
(2) – ground tance
WA200-6 35

Connecting parts among fuse No. 4 of fuse box FS1, engine unit
wiring harness, and engine controller are suspected. Inspect them
8
Possible causes
and standard
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
9 Defective engine controller EC3 (female) Starting switch Voltage
ON Min. 24 V
Between (3) and (1)
START Min. 12 V
36 WA200-6
WA200-6 37
Failure code [CA778] Engine Bkup speed sensor error 1

Action code Failure code Engine Bkup speed sensor error
Trouble
Contents of
• Abnormality is detected in signals of engine Bkup speed sensor.
trouble
Action of • Controls Bkup speed sensor with signals of Ne speed sensor.
Problem that
appears on
• Engine output lowers.
machine
Related
information

1
CAM SENSOR Voltage
Defective engine Bkup
speed sensor
Broken engine Bkup speed
Inspect engine Bkup speed sensor directly for breakage or clear-
3 sensor or defective clear-
ance.
ance
4 Broken rotation sensing ring Inspect it for breakage directly.
Possible causes ness without turning starting switch ON.
and standard 5
(Disconnection or defective Wiring harness between EC1 (female) (26) – Resis- Max.
value in normal contact in connector) CAM SENSOR (female) (3) tance 10 z
state
6 ness
CAM SENSOR (female) (3) and ground tance 100 kz
Hot short (Contact with 5V, and carry out troubleshooting.
7
24V circuit) in wiring harness Wiring harness between EC1 (female) (26) –
Voltage Max. 1 V
CAM SENSOR (female) (3) and ground
CAM SENSOR (female) (3), EC1 (female)
8 ness tance 100 kz
(37) – CAM SENSOR (female) (1)
Resis- Min.
CAM SENSOR (female) (3), EC1 (female)
tance 100 kz
(47) – CAM SENSOR (female) (2)
38 WA200-6

Connecting parts among engine Bkup speed sensor, engine wiring
Possible causes connector
and standard • Humidity in connector, entry of dirt or dust, poor insulation
value in normal
state
Between (37) and
(47)
WA200-6 39
Failure code [CA1633] KOMNET datalink timeout error 1

Action code Failure code KOMNET datalink timeout error
Trouble
Contents of • Engine controller detected a communication error in the KOMNET communication circuit used for the
trouble communication between the HST controller and machine monitor.
• Continues the operation from the default mode.
Action of
controller
• If problem is removed, system is returned to normal operating state.
Problem that
• KOMNET communication information may not be transmitted correctly to cause incorrect operation
appears on
of machine. (Problem depends on failure occurrence location.)
machine
Related • If failure code [DAJRKR] is indicated simultaneously, carry out troubleshooting for it first.
information • Method of reproducing failure code: Turn the starting switch ON.

CAN1 (male) Resistance
Defective CAN end point Between (A) and (B) 110 – 140 z
1
resistance a Prepare with starting switch OFF, then carry out troubleshooting
Between (A) and (B) 110 – 140 z
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – HST (female) (28), (38) tance
Max. 1 z
Disconnection in wiring har- (47) – L29 (female) (3), (8) tance
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) – L72 (female) (22), (32) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Max. 1 z
40 WA200-6

Min. 1 Mz
(47) – HST (female) (28), (38) and ground tance
Min. 1 Mz
Ground fault in wiring har- (47) – L29 (female) (3), (8) and ground tance
3 Min. 1 Mz
Possible causes (Short circuit with ground cir- (47) – L72 (female) (22), (32) and ground tance
and standard cuit) Wiring harness between EC2 (female) (46), Resis-
value in normal Min. 1 Mz
(47) – L80 (female) (7), (8) and ground tance
state
Min. 1 Mz
(47) – CAN1 (female) (A), (B) and ground tance
Min. 1 Mz
a If above troubleshootings 1 – 3 have not identified the cause of
Defective machine monitor, the trouble, failure on the machine monitor, HST controller,
4 HST controller, engine con- engine controller or KOMTRAX terminal should be suspected.
troller or KOMTRAX terminal (Since trouble is in system, troubleshooting cannot be carried
out.)
WA200-6 41
42 WA200-6
WA200-6 43
Failure code [CA2185] Throttle sensor supply voltage high error 1

Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Short circuit in wiring har- Wiring harness among all pins between EC2
Resis- Min.
1 ness (female) (22) – EC2 (female) (PD1 and 2,
tance 100 kz
(with another wiring harness) too, is disconnected.)
Possible causes
and standard Between EC2 (female) (22) – EC3 (female) Resis- Min.
value in normal (3) (PD1 and 2, too, is disconnected.) tance 100 kz
state Connecting parts among accelerator pedal dial, engine unit wiring
connector
44 WA200-6
WA200-6 45
Failure code [CA2186] Throttle sensor power supply low error 1

Action code Failure code Throttle sensor power supply voltage low error
Trouble
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

1 ness
PD1 (female) (1) and ground tance 100 kz
Possible causes
and standard 2 ness Wiring harness among all pins between EC2
(with another wiring harness) (female) (9) – EC2 (female) (PD1 and 2, too, Resis- Min.
value in normal tance 100 kz
state is disconnected.)
Connecting parts among accelerator pedal, engine unit wiring har-
connector
46 WA200-6
WA200-6 47
Failure code [CA2249] Supply pump pressure very low error 2 1

Action code Failure code Supply pump pressure very low error 2
Trouble
Contents of
• No-pressure feed (2) occurred in common rail circuit.
trouble
Problem that • Starting performance is poor
appears on • Exhaust smoke is black.
machine • Engine output lowers.
Related
information

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
48 WA200-6
WA200-6 49
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 1

Action code Failure code Abnormality in IMV (IMA) solenoid
Trouble
Contents of
• Resistance in supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
machine
Related
information

Defective supply pump actu- CP3 PUMP REGULATOR (male) Resistance
2
ator
3 Max. 5 z
(Disconnection or defective CP3 PUMP REGULATOR (female) (1) tance
Possible causes Max. 5 z
CP3 PUMP REGULATOR (female) (2) tance
and standard
value in normal
state
(Contact with ground circuit) CP3 PUMP REGULATOR (female) (1) and Resis- Min.
tance 100 kz
ground
connector
50 WA200-6
WA200-6 51
Failure code [CA2555] Intake heater relay disconnection error 1

Action code Failure code Intake heater relay disconnection error
Trouble
Contents of
• There is disconnection in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
• The input state (boost temperature) can be checked with the monitoring function (Code : ENGINE,
Related 18500, CHG TEMP)
information • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or
less.

without turning starting switch ON. (Test relay unit).
Resistance
Between E06 and ground
Defective heater relay 300 – 600 z
1
(Internal disconnection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
ness Wiring harness between EC2 (female) (40) – Resis- Max.
2
(Disconnection or defective E06 tance 10 z
Possible causes
contact in connector) Wiring harness between heater relay R90 – Resis- Max.
and standard
value in normal R20 tance 10 z
state a Prepare with starting switch OFF, then carry out troubleshooting
(with another wiring harness) (female) (40) – EC2 (female) (E06, too, is Resis- Min.
tance 100 kz
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
connector
Between (40) and ground 300 – 600 z
52 WA200-6
WA200-6 53
Failure code [CA2556] Intake heater relay short circuit error 1

Action code Failure code Intake heater relay short circuit error
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
• The input state (boost temperature) can be checked with the monitoring function (Code : ENGINE,
Related 18500, CHG TEMP)
information • Method of reproducing failure code: Turn the starting switch ON when boost temperature is –4°C or
less.

without turning starting switch ON. (Test relay unit).
Resistance
Between E06 and ground
Defective heater relay 300 – 600 z
1
(Internal short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
2 ness
Possible causes (Contact with ground circuit) Wiring harness between EC2 (female) (40) – Resis- Min.
and standard E06 tance 100 kz
state Short circuit in wiring har- without turning starting switch ON.
(with another wiring harness) (female) (40) – EC2 (female) (E06, too, is Resis- Min.
tance 100 kz
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
connector
Between (40) and ground 300 – 600 z
54 WA200-6
WA200-6 55
SEN03739-00

© 2007 KOMATSU
All Rights Reserved
56
SEN03740-00
WA200-6
WA200-6 70001 and up
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ............................................................. 4
Failure code [D192KY] ECSS solenoid relay: Hot short ................................................................................. 6
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................... 8
Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 10
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 12
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 14
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 16
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 18
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 22
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 24
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 26
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 28
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 30
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 32
WA200-6 1
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 34
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 36
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 38
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 39
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 45
2 WA200-6
WA200-6 3
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short

Action code Failure code Backup alarm/lamp relay 1 circuit: Hot short
Trouble
E01 D160KY (Machine monitor system)
Contents of • Since there is hot short in backup alarm/lamp relay 1 output system, backup lamp relay 1 does not
trouble operate.
• Turns output to backup alarm/lamp relay 1 OFF.
Action of
• If hot short occurs while alarm buzzer is in operation, output is turned OFF.
machine monitor
• If hot short occurs while ECSS is in operation, output is turned OFF.
• Backup lamp is kept ON.
Problem that
• Backup alarm is kept ON.
appears on
• Alarm buzzer may not sound.
machine
• ECSS may not operate.
• Output state (ON/OFF) to backup alarm/lamp relay 1 can be checked with monitoring function.
(Monitoring code: MONITOR PANEL – 40952 – D-OUT-2)
• Operating condition of alarm buzzer can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 40952 – D-OUT-0)
information • Operating condition of ECSS can be checked with monitoring function.
• Method of reproducing failure code: Turn starting switch ON + Set FNR (directional) lever or switch to
R (Reverse) position.

troubleshooting.
Condition becomes Relay (L109) is
Replace backup lamp normal. defective.
relay (L109) with
Defective backup alarm/lamp another relay. Condition does not Relay (L109) is
1
relay (L109) (Internal defect) become normal. normal
Possible causes
and standard
value in normal Resis- 200 – 400
Between L109 (male) (1) – (2)
state tance z
Hot short (Contact with 24V (Set FNR (directional) lever or switch to R (Reverse) position.)
2
circuit) in wiring harness
Wiring harness between L24 (female) (12) –
Voltage Max. 1 V
L109 (female) (2)
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
4 WA200-6
WA200-6 5
Failure code [D192KY] ECSS solenoid relay: Hot short

Action code Failure code ECSS solenoid relay: Hot short
Trouble
E01 D192KY (Machine monitor system)
Contents of • Since there is hot short in ECSS solenoid relay output system, ECSS solenoid relay does not oper-
trouble ate.
• Turns output to ECSS solenoid relay OFF.
Action of
• If hot short occurs while backup alarm/lamp is in operation, output is turned OFF.
machine monitor
• If hot short occurs while alarm buzzer is in operation, output is turned OFF.
Problem that • ECSS does not operate.
appears on • Backup alarm/lamp may not sound.
machine • Alarm buzzer may not operate.
• Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function.
• Operating condition of backup alarm/lamp can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 40952 – D-OUT-2)
information • Operating condition of alarm buzzer can be checked with monitoring function.
• This fault is not detected if ECSS is not installed.
• Method of reproducing failure code: Travel at speed higher than 5 km/h.

troubleshooting.
Replace ECSS sole- normal. defective.
noid relay (L110) with
Defective ECSS solenoid another relay. Condition does not Relay (L110) is
1
relay (L110) (Internal defect) become normal. normal.
value in normal Resis- 200 – 400
state Between L110 (male) (1) – (2)
tance z
Hot short (Contact with 24V and carry out troubleshooting.
2
circuit) in wiring harness Between wiring harness L24 (female) (11) –
Voltage Max. 1 V
L110 (female) (2) and ground
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
6 WA200-6
WA200-6 7
Failure code [D1B0KA] HST safety relay: Disconnection

Action code Failure code HST safety relay: Disconnection
Trouble
E03 D1B0KA (HST controller system)
Contents of
• Disconnection was detected in HST safety relay circuit when starting switch is turned ON.
trouble
• Turns clutch EPC solenoid output OFF.
• Turns motor 1 solenoid output OFF.
Action of
• Turns HST safety relay output OFF.
machine monitor
• Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
• Traction force decreases.
Problem that
• Travel speed is not limited with speed range selector switch and travel speed control dial.
appears on
• If engine is stopped without applying parking brake securely on slope, machine moves down sud-
machine
denly.
• If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
• Following output command values can be checked with monitoring function.
Related
Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA)
information
HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA)

troubleshooting.
Replace HST safety normal. defective.
relay (L111) with
Defective HST safety relay another relay. Condition does not Relay (L111) is
1
(Internal defect) become normal. normal.
Resis- 200 – 400
tance z
troubleshooting.
Replace VIS power Condition becomes Relay (L102) is
supply holding relay normal. defective.
Possible causes Defective VIS power supply (L102) with another Condition does not Relay (L102) is
and standard 2 holding relay (Internal short relay. become normal. normal.
value in normal circuit)
Resis- 200 – 400
tance z
Disconnection in wiring har- Wiring harness between HST (female) (17) – Resis-
Max. 1 z
ness (Disconnection in wiring L111 (female) (2) tance
3
or defective contact in con- Wiring harness between L102 (female) (3) – Resis-
nector) Max. 1 z
L111 (female) (1) tance
Wiring harness between fuse FS1 (No. 3) – Resis-
Max. 1 z
4 Defective HST controller
HST Voltage
Between (17) – ground Max. 1 V
8 WA200-6
WA200-6 9
Failure code [D1B0KB] HST safety relay: Ground fault

Action code Failure code HST safety relay: Ground fault
Trouble
E01 D1B0KB (HST controller system)
Contents of
• Ground fault was detected in HST safety relay circuit when starting switch is turned ON.
trouble
Action of
machine monitor
Problem that
appears on
machine
denly.
Related Motor 1 solenoid output: HST – 80000 – MOTOR SOL DIR (mA)
information HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA).

troubleshooting.
relay (L111) with
1
Possible causes
and standard
value in normal
state Resis- 200 – 400
tance z
2 ness (Contact with GND cir-
cuit) Between wiring harness (HST (female) (17) Resis-
Min. 1 Mz
– L111 (female) (2) and ground tance
If causes 1 and 2 are not detected, HST controller may be defective.
10 WA200-6
WA200-6 11
Failure code [D1B0KY] HST safety relay: Hot short

Action code Failure code HST safety relay: Hot short
Trouble
E03 D1B0KY (HST controller system)
Contents of
• Hot short was detected in HST safety relay circuit.
trouble
Action of
machine monitor
Problem that
appears on
machine
denly.
• If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
Related
information
Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA).

troubleshooting.
relay (L111) with
1
Possible causes
and standard
value in normal
state Resis- 200 – 400
tance z
2
circuit) in wiring harness Between wiring harness HST (female) (17) –
Voltage Max. 1 V
If causes 1 and 2 are not detected, HST controller may be defective.
12 WA200-6
WA200-6 13
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection

Action code Failure code IGN C system: Ground fault/Disconnection
Trouble
E01 D5ZHL6 (Machine monitor system)
• Machine monitor detected disconnection or ground fault in C terminal system.
(When engine speed is above 500 rpm and there is alternator R terminal voltage and starting switch
Contents of
is ON, there is not C terminal signal input.)
trouble
a If engine speed above 250 rpm is sensed in 3 seconds after starting switch is turned ON, however,
error is not detected.
Action of • None in particular.
machine monitor • When starting switch is turned OFF after trouble is repaired, system is reset.
Problem that
appears on • Engine cannot be started (It may be able to be started, depending on faulty part).
machine
• Input state (ON/OFF) from starting switch C terminal to machine monitor be checked with monitoring
Related function.
information (MONITOR PANEL – 40900 – D-IN-2)
• Method of reproducing failure code: Turn starting switch to START position.

a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Defective starting switch Starting switch
1 L02 Voltage
(Internal defect) position
START 20 – 30 V
OFF/ON Max. 1 V
Disconnection in wiring har- Wiring harness between L106 (female) (5) – Resis-
Max. 1 z
ness (Disconnection in wiring L25 (female) (2) tance
2
or defective contact in con- Wiring harness between L02 (female) (3) – Resis-
nector) Max. 1 z
Possible causes
Wiring harness between L79 (female) (6) – Resis-
value in normal
Between wiring harness L02 (female) (3) – Resis-
Ground fault in wiring har- Min. 1 Mz
L79 (female) (8) and ground tance
cuit) Between wiring harness L79 (female) (6) – Resis-
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Starting switch
4 Defective machine monitor L25 Voltage
position
START 20 – 30 V
OFF/ON Max. 1 V
14 WA200-6
WA200-6 15
Failure code [DAF3KK] UNSW power supply: Ground fault/

Disconnection
Action code Failure code UNSW power supply: Ground fault/Disconnection
Trouble
E01 DAF3KK (Machine monitor system)
Contents of • When accessory power supply (power supply for operation) voltage is above 17 V, UNSW power
trouble supply (power supply for memory) has ground fault.
Action of
machine monitor
Problem that • Service meter time gains or loses.
appears on • Odometer does not advance.
machine • Fault history data is not saved.
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Possible causes 1 ness (Contact with GND cir-
cuit) Between wiring harness battery relay R01 – Resis-
and standard Min. 1 Mz
L24 (female) (4), (5) and ground tance
value in normal
Between L24 (female) (4), (5) – (9), (10),
Voltage 20 – 30 V
(17), (18), (19), (20)
16 WA200-6
WA200-6 17
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection

Action code Failure code Machine monitor CAN-NET Signal: Disconnection
Trouble
E03 DAFRKR (HST controller system)
Contents of
• HST controller cannot get information from machine monitor
trouble
Action of
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
machine monitor
Problem that
appears on • The monitor does not display normally
machine
Related
information

1
value in normal Wiring harness between HST (female) (28), Resis-
Max. 1 z
state (38) – L80 (female) (7), (8) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
ness Wiring harness between HST (female) (28), Resis-
2 Max. 1 z
(Disconnection or defective (38) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – C140 (female) (28), (38) tance
Max. 1 z
Max. 1 z
18 WA200-6

Min. 1 Mz
Min. 1 Mz
Grounding fault in wiring har-
3 ness (Contact with ground Min. 1 Mz
(38) – EC2 (female) (46), (47) and ground tance
circuit)
Possible causes Wiring harness between HST (female) (28), Resis-
Min. 1 Mz
and standard (38) – C140 (female) (28), (38) and ground tance
Min. 1 Mz
state (38) – CAN1 (female) (A), (B) and ground tance
Min. 1 Mz
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of machine monitor
mating of the connector.
out.)
WA200-6 19
20 WA200-6
WA200-6 21
Failure code [DAJ0KK] HST controller power supply: Low voltage

Action code Failure code HST controller power supply: Low voltage
Trouble
E03 DAJ0KK (HST controller system)
• Low voltage was detected in HST controller power supply.
Contents of
(While engine was running and alternator voltage was above 20 V, controller voltage was below 18
trouble
V.)
• Turns all outputs OFF.
Action of
• Trouble which may be detected wrongly is not detected.
machine monitor
Problem that
• Machine cannot travel (in either direction).
appears on
• Another trouble may be detected.
machine
Related • If gear is set in neutral and engine is restarted while controller voltage is above 20 V, system is reset.
information • Method of reproducing failure code: Turn starting switch ON

1 Defective (Broken) fuse Check fuse FS1 (No. 3) directly.
Possible causes ness (Disconnection in wiring Wiring harness between HST (female) (1) – Resis-
2 Max. 1 z
and standard or defective contact in con- fuse FS1 (No. 3) tance
value in normal nector) Wiring harness between HST (female) (11) – Resis-
state Max. 1 z
fuse FS1 (No. 3) tance
HST Voltage
Between (1), (11) – ground 20 – 30 V
22 WA200-6
WA200-6 23
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality

Action code Failure code HST controller memory (EEPROM): Abnormality
Trouble
E01 DAJ0KT (HST controller system)
Contents of
• Information in HST controller ROM (non-volatile memory) is abnormal.
trouble
Action of • Sets internal adjustment values to defaults.
machine monitor • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Performance may lower. For example, shift-down feel from 3rd or 4th gear speed may become bad.
machine
Related
information

• Carry out troubleshooting according to the following procedure.
1. Change set information of HST controller.
(Example: Change HST selection to B.)
2. Turn starting switch OFF.
Possible causes 3. Wait for at least 30 seconds, then turn starting switch ON again.
and standard 4. At this time, check that set information is reflected.
value in normal 1 Defective HST controller (Example: See if HST selection is kept at B and value is returned
state to default A.)
<Diagnosis>
Set information is not reflected
(Value is returned to default): HST controller is defective.
Set information is reflected
(Value is not returned to default): HST controller is normal.
24 WA200-6
WA200-6 25
Failure code [DAJ1L4] HST controller main power line: Disconnection/

Ground fault
Action code Failure code HST controller main power line: Disconnection/Ground fault
Trouble
E01 DAJ1L4 (HST controller system)
Contents of
• Low voltage was detected in HST controller main power line (battery relay drive voltage system).
trouble
Action of
• Starts starting key OFF processing earlier.
machine monitor
Problem that
appears on • Machine is not affected in particular.
machine
Related
information

ness (Disconnection in wiring without turning starting switch ON.
Possible causes 1
or defective contact in con- Wiring harness between HST (female) (13) – Resis-
and standard nector) Max. 1 z
D09 (female) (1), D10 (female) (1) tance
value in normal
HST (female) Voltage
Between (13) – ground 20 – 30 V
26 WA200-6
WA200-6 27
Failure code [DAJ1L6] HST controller main power line: Hot short
Action code Failure code HST controller main power line: Hot short
Trouble
Contents of
• Hot short was detected in HST controller main power line (battery relay drive voltage system).
trouble
• Continues key OFF processing on assumption that battery relay is turned OFF.
Action of (Turns controller self-holding circuit OFF on assumption that alternator L signal voltage system is
machine monitor turned OFF.)
• Displays error next time when starting switch is turned ON.
Problem that
appears on • Battery voltage may lower earlier.
machine
Related
• After error is detected, it is displayed next time when starting switch is turned ON.
information

Between wiring harness HST (female) (13) –
D09 (female) (1), circuit branch end and Voltage Max. 1 V
ground
Hot short (Contact with 24V
Possible causes 1 Wiring harness between L02 (female) (2) –
and standard D10 (female) (2), circuit branch end and Voltage Max. 1 V
value in normal ground
state Wiring harness between E02 (female) (1) –
D09 (female) (2), circuit branch end and Voltage Max. 1 V
ground
a Prepare with starting switch OFF, then turn starting switch ON to
OFF and carry out troubleshooting.
28 WA200-6
WA200-6 29
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage

Action code Failure code Controller solenoid power supply: Low voltage
Trouble
E03 DAJ2KK (HST controller system)
• Low voltage was detected in controller solenoid power supply system.
Contents of
(While VIS power supply self-holding relay is ON and battery voltage is above 20 V, solenoid power
trouble
supply voltage below 18 V was detected.)
Action of
• Turns all outputs OFF.
machine monitor
Problem that
• Machine cannot travel.
appears on
• Another failure may not be detected.
machine
Related
• If gear is set in neutral and engine is restarted while solenoid voltage is above 19 V, system is reset.
information

(L102) with another Condition does not Relay (L102) is
Defective VIS power supply relay. become normal. normal.
1
holding relay (Internal defect) a Prepare with starting switch OFF, then check unit.
When 24 V is applied Resis-
Max. 1 z
between (1) – (2) tance
Possible causes Between terminals of
and standard L102 (male) (3) – (5) When no voltage is Resis-
applied between (1) – Min. 1 Mz
value in normal tance
(2)
state
2
nector) Max. 1 z
3 Defective HST controller Max. 1 z
fuse FS1 (No. 3) tance
HST Voltage
30 WA200-6
WA200-6 31
Hot short in wiring harness
Action code Failure code HST controller load power supply holding line: Hot short in wiring
Trouble harness
Contents of • Hot short was detected in HST controller load power supply holding line.
trouble (When output command was ON, output terminal voltage above 5.7 V was detected.)
Action of
• Turns output OFF (Control protection function works).
machine monitor
Problem that • If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on down suddenly.
machine • If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.
Related
information

Defective VIS power supply (L102) with another Condition does not Relay (L102) is
1
holding relay (Internal defect) relay. become normal. normal.
Possible causes without turning starting switch ON.
and standard
Resis- 200 – 400
value in normal Between L102 (male) (1) – (2)
tance z
state
2
Voltage Max. 1 V
HST Voltage
32 WA200-6
WA200-6 33
Disconnection/Ground fault
Action code Failure code HST controller load power supply holding line: Disconnection/
Trouble Ground fault
• Disconnection or ground fault was detected in load power supply holding line during HST controller
Contents of
final check.
trouble
(During final check, when output command was OFF, voltage below 5.7 V was detected.
Action of
• Relay cannot be driven while there is disconnection.
machine monitor
Problem that • If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on down suddenly.
machine • If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.
Related
information

and OFF, wait for 30 seconds, and turn it ON again and carry out
troubleshooting.
Defective HST safety relay (L102) with another
1 Condition does not Relay (L102) is
(Internal defect) relay. become normal. normal.
Resis- 200 – 400
tance z
Possible causes
state ness (Disconnection in wiring Wiring harness between HST (female) (7) – Resis-
2 Min. 1 Mz
nector) Wiring harness between L102 (female) (1) – Resis-
Min. 1 Mz
fuse FS1 (No.3) tance
cuit) Between wiring harness HST (female) (7) – Resis-
Min. 1 Mz
HST Voltage
34 WA200-6
WA200-6 35
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range

Action code Failure code Sensor 5V power supply: Out of output range
Trouble
E03 DAJ5KX (HST controller system)
Contents of
• Sensor 5V power supply of HST controller is below 4.7 V or above 5.3 V.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
machine monitor • Even if cause of failure disappears, system does not reset itself until engine is started again.
Problem that
• If this trouble occurs during travel, travel speed may not increase or traction force may be insufficient.
appears on
• Once machine stops, maximum travel speed is about 4 km/h.
machine
• If there is disconnection or ground fault, [DHH1KX], [DDD7KX] or [DF10KA] is displayed, too.
Related
• If there is hot short, [DHH1KY], [DDD7KY] or [DF10KB] is displayed, too.
information
• If this failure occurs during travel, [DLT4KX] or [DLT3KX] may be displayed, too.

Defective travel speed con- Travel speed control
Disconnect devices at L54
trol dial, defective speed dial
range selector switch, defec- right in order. If failure
1 code [DAJ5KX] lights Speed range selector
tive resistor, defective travel L03
up (reset is indicated) switch
speed sensor, or defective
HST pressure sensor when a device is dis- Resistor L70
connected, that device Travel speed sensor T09
has trouble in it.
HST pressure sensor T11
and standard Ground fault in wiring har-
value in normal 2 ness (Contact with GND cir- Between wiring harness HST (female) (22) –
cuit) L54 (female) (A) or L70 (female) (2), (4) or Resis-
state Min. 1 Mz
T09 (female) (1) or T11 (female) (B) and tance
ground
troubleshooting.
Hot short (Contact with 24V Between wiring harness HST (female) (22) –
3
circuit) in wiring harness L54 (female) (A) or L70 (female) (2), (4) or
Voltage Max. 1 V
T09 (female) (1) or T11 (female) (B) and
ground
HST Voltage
Between (22) – (32) 4.7 – 5.3
36 WA200-6
WA200-6 37
Failure code [DAJ9KQ] HST controller model selection: Disagreement

of model selection signals
Action code Failure code HST controller model selection: Disagreement of model selection
Trouble
E03 DAJ9KQ signals (Machine monitor system)
Contents of
• The HST controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
• Does not display failure codes which may be false detected.
Problem that
appears on • Continuing the travel in this condition may damage the HST.
machine
Related
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting)
state HST controller part number Confirm the part number of the HST controller. It must be replaced if
2
error it is not the specified controller.
38 WA200-6
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

Action code Failure code HST controller CAN-NET signal: Disconnection
Trouble
E03 DAJRKR (Machine monitor system)
Contents of
• Machine monitor cannot get information from HST controller
trouble
• Uses CAN information that was sent from HST controller before the occurrence of the error.
Action of
machine monitor
Problem that
• The monitor does not display normally
appears on
• If HST controller power supply circuit is defective, machine cannot travel in either direction.
machine
Related
information

1
Max. 1 z
state (38) – L80 (female) (7), (8) tance
Max. 1 z
ness Wiring harness between HST (female) (28), Resis-
2 Max. 1 z
(Disconnection or defective (38) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) – C140 (female) (28), (38) tance
Max. 1 z
Max. 1 z
WA200-6 39

Min. 1 Mz
Min. 1 Mz
3 ness Min. 1 Mz
(38) – EC2 (female) (46), (47) and ground tance
(Contact with ground circuit)
Possible causes Wiring harness between HST (female) (28), Resis-
(38) – C140 (female) (28), (38) and ground tance
value in normal
state Min. 1 Mz
Min. 1 Mz
a Carry out troubleshooting in "When HST controller power supply
circuit is defective" described later.
out.)
40 WA200-6
WA200-6 41
When HST controller power supply circuit is defective

Broken fuse box FS1 fuse
a If fuse is broken, circuit probably has ground fault etc. (See cause c.)
No. 3
b
or defective contact in con- Wiring harness between fuse box FS1 fuse Resis-
nector) Max. 1 z
No. 3 – HST (female) (1) (11). tance
Between wiring harness fuse box FS1 fuse
Resis-
No. 3 – HST (female) (1) (11), branch end Min. 1 Mz
tance
and ground
Min. 1 Mz
branch end and ground tance
Min. 1 Mz
D07 (female) (1), T07 (3) and ground tance
Min. 1 Mz
Ground fault in wiring har- D08 (female) (1), T07 (1) and ground tance
c ness (Contact with GND cir- Between wiring harness L104 (female) (5) – Resis-
cuit) Min. 1 Mz
R59 (female) (1) and ground tance
Between wiring harness L63 (female) (5), (1) Resis-
Min. 1 Mz
– HST (female) (25) and ground tance
Possible causes
Between wiring harness L15 (female) (3),
and standard Resis-
D01 (female) (5) – HST (female) (5) and Min. 1 Mz
value in normal tance
ground
state
Min. 1 Mz
HST (female) (34) and ground tance
Between wiring harness L15 (female) (4) –
Resis-
L126 (female) (1), HST (female) (15) and Min. 1 Mz
tance
ground
Between (5) – (6) 200 – 400 z
a Prepare with starting switch OFF.
a Test relay unit.
Directional pressure
(1) – (2) Resistance
Defective directional pres- selector relay (L101)
d sure selector relay (L101) When 24 V is applied
(Internal short circuit) Max. 1 z
(relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(relay is "OFF")
a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Replace directional pressure selector relay (L101) with another
relay. If condition becomes normal, directional pressure selector
relay is defective.
42 WA200-6

Between (1) – (2) 200 – 400 z
a Test relay unit.
Backup alarm/lamp
Defective backup alarm/lamp (1) – (2) Resistance
relay (L126)
e relay (L126) (Internal short
circuit) When 24 V is applied
Max. 1 z
(relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(relay is "OFF")
Possible causes
Replace backup alarm/lamp relay (L126) with another relay. If con-
and standard
dition becomes normal, backup alarm/lamp relay is defective.
value in normal
Defective directional pres- without turning starting switch ON.
f sure selector solenoid (Inter-
nal short circuit) Resis-
Between T07 (male) (3) – T07 (male) (4) 20 – 30 z
tance
Defective motor 2 solenoid without turning starting switch ON.
g
(Internal short circuit) Resis-
Between T07 (male) (1) – T07 (male) (2) 20 – 30 z
tance
Defective fan reverse sole- without turning starting switch ON.
h
noid (Internal short circuit) Resis-
Between R59 (male) (1) – R59 (male) (2) 35 – 45 z
tance
i Defective HST controller
HST Voltage
Between (1), (11) – ground 20 – 30 V
WA200-6 43
Related circuit diagram (When HST controller power supply circuit is defective)
44 WA200-6
Failure code [DAJRMA] HST controller: Disagreement in option

selection
Action code Failure code HST controller: Disagreement in option selection
Trouble
E03 DAJRMA (Machine monitor system)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition by
trouble done the HST controller.
Action of • The HST controller follows the option setting being recognized by itself.
Problem that
appears on • The option setting does not work normally.
machine
Related
information

Set the option setting using the option select function of the
Possible causes 1 Defective option setting machine monitor (See Special functions of machine monitor
and standard (EMMS) in Testing and adjusting)
value in normal The machine monitor may be defective. (Since trouble is in system,
state 2 Defective machine monitor
troubleshooting cannot be carried out.)
The HST controller may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
WA200-6 45
SEN03740-00

© 2007 KOMATSU
All Rights Reserved
46
SEN03741-00
WA200-6
WA200-6 70001 and up
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line......................................... 3
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................... 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short ................................................... 12
Failure code [DDB6KB] Parking brake switch B: Ground fault ..................................................................... 14
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch
(intermediate switch): Trouble................................................................................................................ 16
Failure code [DDB6L0] Parking brake switch A: Ground fault ...................................................................... 18
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short.................................................... 20
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 22
Failure code [DDD7KY] Travel speed control dial signal: Hot short.............................................................. 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection............................................ 26
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault .................................................................. 28
Failure code [DDK6KY] FNR lever: Hot short ............................................................................................... 32
WA200-6 1
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)................................ 34
2 WA200-6
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in

signal line
Action code Failure code Engine controller CAN-NET: Disconnection in signal line
Trouble
E03 DB2RKR (HST controller system)
Contents of
• Communication via CAN signal line between the HST controller and engine controller is defective.
trouble
• Uses CAN information that was sent from engine controller before the occurrence of the error.
• Once engine stops, recognized engine speed is fixed to low idle.
Action of
• Once engine stops, recognized operating degree of accelerator is fixed to 0%.
controller
Problem that
• The monitor does not display normally
appears on
• If engine controller power supply circuit is defective, engine stops.
machine
Related
information

Defective CAN end point Between (A) – (B) 110 – 140 z
1
Between (A) – (B) 110 – 140 z
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – HST (female) (28), (38) tance
Max. 1 z
2 Max. 1 z
(Disconnection or defective (47) – L29 (female) (3), (8) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – C140 (female) (28), (38) tance
Max. 1 z
Max. 1 z
WA200-6 3

Min. 1 Mz
(47) – HST (female) (28), (38) and ground tance
Min. 1 Mz
3 ness Min. 1 Mz
Possible causes Wiring harness between EC2 (female) (46), Resis-
(47) – C140 (female) (28), (38) and ground tance
value in normal
state Min. 1 Mz
Min. 1 Mz
Defective power supply cir- • Carry out troubleshooting for "When engine controller power sup-
4
cuit of engine controller ply is defective" described later.
out.)
4 WA200-6
WA200-6 5
When engine controller power supply circuit is defective

Defective fuse No. 4 in fuse If fuse box is damaged, circuit probably has ground fault etc.
a
box FS1 or No. 15 in FS2 (See cause c.)
Wiring harness between fuse box FS1, No. 4 Resis-
Max. 1 z
fuse – L107 (female) (3), L108 (female) (3) tance
Max. 1 z
Disconnection in wiring har- L108 (female) (5) – EC3 (female) (3), (4) tance
ness (Disconnection in wiring Wiring harness between EC3 (female) (1), Resis-
b Max. 1 z
or defective contact in con- (2) – ground tance
Max. 1 z
L107 (female) (1), L108 (female) (1) tance
Max. 1 z
L108 (female) (2) – EC2 (female) (33) tance
Max. 1 z
EC2 (female) (39) tance
Between wiring harness fuse box FS1, No. 4
Resis-
fuse – L107 (female) (3), L108 (female) (3) Min. 1 Mz
tance
Possible causes and ground
and standard Ground fault in wiring har- Between wiring harness L107 (female) (5),
Resis-
value in normal c ness (Contact with GND cir- L108 (female) (5) – EC3 (female) (3), (4) and Min. 1 Mz
tance
state cuit) ground
Resis-
L107 (female) (1), L108 (female) (1) and Min. 1 Mz
tance
ground
Min. 1 Mz
EC2 (female) (39) and ground tance
L107, L108 (male) Resistance
Between (1) – (2) 200 – 400 z
a Check relay unit.
Engine controller cut
Defective engine controller (1) – (2) Resistance
relay (L107, L108)
d cut relay (L107, L108) (Inter-
nal defect) When 24 V is applied
Max. 1 z
(relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(relay is "OFF")
Replace engine controller cut relay (L107, L108) with another relay.
If condition becomes normal, engine controller cut relay is defective.
6 WA200-6

Possible causes EC2 Voltage
and standard Between (33) – ground Max. 1 V
value in normal e Defective engine controller
state Between (39) – ground 20 – 30 V
EC3 Voltage
Between (3), (4) – ground 20 – 30 V
Between (1), (2) – ground Max. 1 V
Related circuit diagram (When engine controller power supply circuit is defective)
WA200-6 7
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality

Action code Failure code Fan automatic reverse switch signal: Abnormality
Trouble
E01 DD1NL4 (HST controller system)
Contents of • Because of hot short in fan automatic reverse switch system, fan automatic reverse switch input and
trouble fan manual reverse switch input were sensed simultaneously.
Action of
• Turns automatic reverse switch function OFF.
controller
Problem that
• After error is detected, fan does not reverse.
appears on
• Automatic reverse switch LED lamp keeps lighting.
machine
• Input state from fan automatic reverse switch can be checked with monitoring function
Related
(Code: HST – 93400 – FAN REVERSE SW) (Code: MONITOR PANEL – 40901 – D-IN-9).
information
• Method of reproducing failure code: Turn starting switch ON and fan automatic reverse switch ON.

Defective fan automatic Fan automatic reverse
1 reverse switch (Internal short L69 (male) Resistance
switch
circuit)
ON Max. 1 z
Between (3), (4) – (5)
OFF Min. 1 Mz
value in normal Hot short in wiring harness (Carry out troubleshooting with automatic reverse switch OFF)
2
state (Contact with 24V circuit)
Voltage Max. 1 V
L69 (female) (3), (4) and ground
Fan automatic reverse
3 Defective machine monitor L25 (male) Voltage
switch
Between (14) and ON 20 – 30 V
ground OFF Max. 1 V
8 WA200-6
WA200-6 9
Failure code [DD1NLD] Fan reverse switch signal: Abnormality

Action code Failure code Fan reverse switch signal: Abnormality
Trouble
E01 DD1NLD (HST controller system)
Contents of • Since the fan manual reverse switch system is shorted with the power source, the fan manual
trouble reverse switch remains at ON position. (Continuation for 30 seconds determines fault)
Action of
controller
Problem that
appears on • Fan remains in the reverse rotation
machine
• The input state (ON/OFF) from the fan manual reverse switch can be checked with the monitoring function
Related (Code: HST – 93400 – FAN REVERSE SW).
information (Code: MONITOR PANEL – 40900 – D-IN-1).

Defective fan reverse switch Fan manual reverse
1 L69 (male) Resistance
(Internal short circuit) switch
Between ON Max. 1 z
(5) – (1), (16) OFF Min. 1 Mz
Possible causes
and standard
Hot short in wiring harness and carry out troubleshooting.
value in normal 2
state (Contact with 24V circuit) Wiring harness between L25 (female) (10) –
Voltage Max. 1 V
L69 (female) (1), (6) and ground
Fan manual reverse
3 Defective machine monitor L25 (male) Voltage
switch
Between (10) and ON 20 – 30 V
ground OFF Max. 1 V
10 WA200-6
WA200-6 11
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short

Action code Failure code Parking brake switch A: Disconnection/Hot short
Trouble
E01 DDB6KA (HST controller system)
• HST controller detected disagreement with parking brake signal from machine monitor.
(While parking brake signal A of machine monitor was input (closed), there was not parking brake
Contents of
signal of HST controller (open).
trouble
• While there was not input signal (switch A was open), signal was input to parking brake switch B
(switch at bottom) (switch B was closed).
Action of
controller
Problem that
• If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on
down suddenly.
machine
• Parking brake switch A : For parking brake remind (Intermediate)
• Parking brake switch B : For parking brake indicator (Bottom)
• Operation of parking brake can be checked with monitoring function.
[Parking brake switch A] (Recognition by machine monitor)
Related
(Monitoring code: MONITOR PANEL – 40903 – D-IN-28 and 40904 – D-IN-35)
information
[Parking brake switch B] (Recognition by machine monitor)
[Parking brake switch A/B] (HST controller recognition)
(Monitoring code: HST – 99100 – PARKING A/B)

Defective diode (See Testing and adjusting, “Test procedure for diode”.)
1
(Internal defect)
Between D02 (male) (6) – (2) Continuity is secured
2
nector) Max. 1 z
Ground fault in wiring har- (Test with parking brake applied.)
3 ness (Contact with GND cir- Between wiring harness HST (female) (16) – Resis- Min.
Possible causes cuit) D02 (female) (5) and ground tance 1 Mz
and standard Between wiring harness L27 (female) (2), Resis- Min.
value in normal (14) – D02 (female) (8) and ground tance 1 Mz
Hot short (Contact with 24V (Test with parking brake released.)
4
Voltage Max. 1 V
D02 (female) (6) and ground
troubleshooting.
5 Defective HST controller (Test with parking brake applied.)
HST Voltage
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
6 Defective machine monitor (Test with parking brake applied.)
L27 Voltage
Between (2) (14) – ground 20 – 30 V
12 WA200-6
WA200-6 13
Failure code [DDB6KB] Parking brake switch B: Ground fault

Action code Failure code Parking brake switch B: Ground fault
Trouble
E01 DDB6KB (HST controller system)
Contents of • While parking brake signal B of machine monitor was not input (open), there was input signal
trouble (switch B was closed).
Action of
controller
Problem that
• Since machine can travel forward and reverse while parking brake is applied, parking brake may be
appears on
damaged (Alarm buzzer sounds in this case, however).
machine
Related
information

Defective diode without turning starting switch ON.
1 (See Testing and adjusting, “Test procedure for diode”.)
(Internal defect)
2
or defective contact in con- Wiring harness between L27 (female) (1), (6) Resis-
nector) Max. 1 z
– L47 (female) (2) tance
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard 3 ness (Contact with GND cir- (Test with parking brake applied.)
value in normal cuit) Between wiring harness HST (female) (16) – Resis- Min.
state D02 (female) (5) and ground tance 1 Mz
troubleshooting.
HST Voltage
5 Defective machine monitor (Test with parking brake released.)
L27 Voltage
Between (1) (6) – ground Max. 1 V
14 WA200-6
WA200-6 15
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking

brake reminder switch (intermediate switch): Trouble
Action code Failure code Parking brake switch (bottom switch) or parking brake reminder
Trouble
E03 DDB6KZ switch (intermediate switch): Trouble (Machine monitor system)
Contents of • Parking brake indicator signal was closed and opening of parking brake reminder signal was
trouble detected.
machine monitor • Turns parking brake indicator and parking brake remind caution lamp ON.
Problem that • While parking brake is in intermediate position, parking brake reminder caution lamp does not light.
appears on • While parking brake is in intermediate position, parking brake reminder buzzer does not sound.
machine • While parking brake is in intermediate position, centralized warning lamp does not light.
• Input state (ON/OFF) of parking brake indicator signal and reminder signal can be checked with
Related monitoring function.
information (Monitoring code: MONITOR PANEL – 40903 – D-IN-26, 28)
(Monitoring code: MONITOR PANEL – 40904 – D-IN-35, 36)

Defective diode (See Testing and adjusting, “Test procedure for diode”.)
1
(Internal defect)
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring (Test with parking brake released.)
2
value in normal or defective contact in con-
nector) Wiring harness between L27 (female) (2), Resis-
state Max. 1 z
(14) – L53 (female) (2) tance
3 ness (Contact with GND cir- (Test with parking brake applied.)
cuit) Between wiring harness L27 (female) (1), (6) Resis- Min.
– D02 (female) (7) and ground tance 1 Mz
If causes 1 – 3 are not detected, machine monitor may be defective.
16 WA200-6
WA200-6 17
Failure code [DDB6L0] Parking brake switch A: Ground fault

Action code Failure code Parking brake switch A: Ground fault
Trouble
E01 DDB6L0 (HST controller system)
Contents of • While parking brake switch A operation signal of machine monitor was not input (open), parking
trouble brake switch A operation signal of HST controller was input (closed).
Action of • When engine is stopped while parking brake is not applied securely, move-down prevention is not
controller controlled.
Problem that
• If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on
down suddenly.
machine
Related
information

(Internal defect)
ness (Disconnection in wiring (Test with parking brake released.)
2
or defective contact in con-
nector) Wiring harness between L27 (female) (2), (14) Resis-
Max. 1 z
– L53 (female) (2) tance
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard 3 ness (Contact with GND cir- (Test with parking brake applied.)
value in normal cuit) Between wiring harness HST (female) (6) – Resis- Min.
state
D02 (female) (6) and ground tance 1 Mz
HST Voltage
L27 Voltage
Between (1) (6) – ground Max. 1 V
18 WA200-6
WA200-6 19
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short

Action code Failure code Parking brake switch B: Disconnection/Hot short
Trouble
E03 DDB6L4 (HST controller system)
Contents of • HST controller detected disagreement with parking brake signal from machine monitor.
trouble (While signal was input to machine monitor (closed), signal was not input to HST controller (open).
Action of • Stops neutralizer (parking brake drag prevention function).
controller • If error is detected during forward or reverse travel, gear is set in neutral.
• Once FNR selector lever or switch is set to N, normal control is started again.
• If error is detected while FNR selector lever or switch is in F or R, machine cannot start until gear is
Problem that
returned to neutral.
appears on
• Since machine can travel forward and reverse while parking brake is applied, parking brake may be
machine
damaged (Caution buzzer sounds in this case, however).
Related
information

(Internal defect)
2
nector) Max. 1 z
3 ness (Contact with GND cir- (Test with parking brake applied.)
cuit) Between wiring harness L27 (female) (1), (6) Resis- Min.
Possible causes
and standard – D02 (female) (7) and ground tance 1 Mz
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short (Contact with 24V and carry out troubleshooting.
4
Voltage Max. 1 V
D02 (female) (5) and ground
5 Defective HST controller (Test with parking brake released.)
HST Voltage
L27 Voltage
Between (1) (6) – ground 20 – 30 V
20 WA200-6
WA200-6 21
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/

Ground fault
Action code Failure code Travel speed control dial signal: Disconnection/Ground fault
Trouble
E01 DDD7KX (HST controller system)
Contents of
• Travel speed control dial signal voltage lowered below 0.3 V.
trouble
Action of • Continue controls on assumption that travel speed control dial is set to minimum speed side.
controller • Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• Travel speed cannot be adjusted with travel speed control dial.
appears on
• If speed range selector switch is set in 1st, travel speed is set to about 5 km/h.
machine
Related
• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information

4.7 – 5.3
Between L54 (female) (A) – (C) Voltage
Defective travel speed con- V
1
trol dial (Internal defect) Between L54 (female) (B) – (C) (Max. speed 0.3 – 0.9
Voltage
side of dial) V
Between L54 (female) (B) – (C) (Min. speed 4.1 – 4.7
Voltage
side of dial) V
ness (Disconnection in wiring Wiring harness between HST (female) (23) – Resis-
2 Max. 1 z
or defective contact in con- L54 (female) (B) tance
Possible causes nector)
and standard Wiring harness between HST (female) (22) – Resis-
Max. 1 z
value in normal L54 (female) (A) tance
cuit) Between wiring harness HST (female) (23) – Resis- Min.
L54 (female) and ground tance 1 Mz
HST (female) Resistance
Between (32) – ground Max. 1 z
4 Defective HST controller a Prepare with starting switch OFF, then turn starting switch ON
Between (22) – ground 4.7 – 5.3 V
22 WA200-6
WA200-6 23
Failure code [DDD7KY] Travel speed control dial signal: Hot short
Action code Failure code Travel speed control dial signal: Hot short
Trouble
E01 DDD7KY (HST controller system)
Contents of
• Travel speed control dial signal voltage exceeded 4.7 V.
trouble
Action of
controller
Problem that
• Travel speed cannot be adjusted with travel speed control dial.
appears on
• If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
machine
Related
• If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information

4.7 – 5.3
Between L54 (female) (A) – (C) Voltage
Defective travel speed con- V
1
trol dial (Internal defect) Between L54 (female) (B) – (C) (Max. speed 0.3 – 0.9
Voltage
side of dial) V
Between L54 (female) (B) – (C) (Min. speed 4.1 – 4.7
Voltage
side of dial) V
2
Possible causes nector) Max. 1 z
L54 (female) (C) tance
and standard
state Hot short (Contact with 24V and carry out troubleshooting.
3
Voltage Max. 1 V
L54 (female) (B) and ground
HST (female) Resistance
Between (32) – ground Max. 1 z
4 Defective HST controller a Prepare with starting switch OFF, then turn starting switch ON
24 WA200-6
WA200-6 25
Failure code [DDE5MA] Emergency steering operation switch:

Disconnection
Action code Failure code Emergency steering operation switch: Disconnection
Trouble
E01 DDE5MA (Machine monitor system)
Contents of • While engine was stopped, steering pump oil pressure was sensed because of disconnection in
trouble steering oil pressure reduction switch (emergency steering operation switch) system.
Action of
machine monitor
Problem that
appears on • When steering oil pressure reduces, steering oil pressure caution lamp does not light.
machine
• This code is applied to only emergency steering specification model and is not turned ON if not
selected as option with machine monitor.
Related
• Input state (ON/OFF) from steering oil pressure reduction switch can be checked with monitoring
information
function.
(Monitoring code: MONITOR PANEL – 40904 – D-IN-39)

and start engine and carry out troubleshooting in each case.
F11 (male) Steering oil pressure Resistance
Defective steering oil pres- Oil pressure reduction
Max. 1 z
1 sure reduction switch (Inter- (Engine is stopped)
nal defect) Between (1) – (2)
Oil pressure normal
Min. 1 Mz
(Engine is running)
Between (1), (2) –
Normally Min. 1 Mz
ground
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between L27 (female) (16) – Resis-
2 Max. 1 z
or defective contact in con- F11 (female) (1) tance
nector) Resis-
Between F11 (female) (2) – ground Max. 1 z
tance
and start engine and carry out troubleshooting in each case.
L27 Steering oil pressure Voltage
3 Defective machine monitor Oil pressure reduction
Max. 1 V
Between (16) – (Engine is stopped)
ground Oil pressure normal
20 – 30 V
(Engine is running)
26 WA200-6
WA200-6 27
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault

Action code Failure code FNR lever: Disconnection/Ground fault
Trouble
E03 DDK6KA (HST controller system)
Contents of • No signal of FNR (directional) lever is input because of disconnection or ground fault in FNR (direc-
trouble tional) lever switch signal system.
• If directional selector switch is not installed, gear is set in neutral.
• If directional selector switch actuation switch is turned OFF, gear is set in neutral (Only machine with
directional selector switch actuation switch).
Action of • If directional selector switch actuation switch is turned ON, FNR (directional) lever switch controls on
controller assumption that gear is in neutral (Only machine with directional selector switch actuation switch).
• Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neu-
tral).
• Machine cannot be driven with FNR (directional) lever.
Problem that
• Machine can be driven with directional selector switch (only machine with directional selector switch
appears on
actuation switch).
machine
• Gear shift lever position lamp goes off.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: HST – 40977 – D-IN-0, D-IN-1 or D-IN-2).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

1
box (FS1) (See cause 5.)
FNR (directional)
L15 Voltage
lever
Between (1) and
Constant 20 – 30 V
Defective FNR (directional) ground
2 lever switch (Internal discon- Between (3) and N (Neutral) 20 – 30 V
nection or short circuit) ground Other than above Max. 1 V
Possible causes F (Forward) 20 – 30 V
Between (2) and
and standard
ground Other than above Max. 1 V
value in normal
state Between (4) and R (Reverse) 20 – 30 V
supply holding relay normal defective
3
holding relay (Internal defect) relay become normal normal
Resis- 200 –
tance 400 z
28 WA200-6

troubleshooting.
Replace neutral normal defective
safety relay (L106)
Defective neutral safety relay with another relay Condition does not Relay (L106) is
4
(Internal short circuit) become normal normal
Resis- 200 –
tance 400 z
Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
box (FS1) – L102 (female) (5) and ground tance
Max. 1 z
ness L15 (female) (1) tance
5
(Disconnection or defective Wiring harness between HST (female) (15) – Resis-
Wiring harness between HST (female) (5) – Resis-
Max. 1 z
Max. 1 z
Possible causes
state Wiring harness between fuse No. 3 of fuse Resis-
Min. 1 Mz
Resis-
L15 (female) (1), circuit branch end and Min. 1 Mz
tance
Grounding fault in wiring har- ground
6 ness Wiring harness between HST (female) (15) –
(Contact with ground circuit) L15 (female) (4), L126 (female) (13) and Resis-
Min. 1 Mz
tance
ground
Wiring harness between HST (female) (5) –
Resis-
L15 (female) (3), D01 (female) (5) and Min. 1 Mz
tance
ground
Min. 1 Mz
FNR (directional)
HST Voltage
lever
Between (5) and N (Neutral) 20 – 30 V
7 Defective HST controller ground Other than above Max. 1 V
Between (34) and F (Forward) 20 – 30 V
Between (15) and R (Reverse) 20 – 30 V
WA200-6 29
30 WA200-6
WA200-6 31
Failure code [DDK6KY] FNR lever: Hot short

Action code Failure code FNR lever: Hot short
Trouble
E03 DDK6KY (HST controller system)
Contents of • Multiple FNR (directional) lever signals are input because of hot short in FNR (directional) lever
trouble switch signal system.
• Sets gear in neutral.
Action of • If directional selector switch actuation switch is turned ON, machine is driven according to directional
controller selector switch setting (only machine with directional selector switch actuation switch).
• Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neu-
tral).
• Operator cannot travel machine at position other than position having hot short with FNR (directional)
Problem that lever switch. (Example: When directional lever F system has hot short, if lever is set in F, trouble is
appears on reset and machine can travel forward.)
machine • Multiple gear shift lever position lamp lights.
• Machine can be driven with directional selector switch (only machine with directional selector switch).
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: HST – 40977 – D-IN-0, D-IN-1 or D-IN-2).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

FNR (directional)
L15 Voltage
lever
Between (1) and
Defective FNR (directional) ground
1 lever switch (Internal short Between (3) and F (Forward) 20 – 30 V
circuit) ground Other than above Max. 1 V
and standard
value in normal Wiring harness between HST (female) (15) –
Voltage Max. 1 V
state Hot short in wiring harness L15 (female) (4) and ground
2
(Contact with 24V circuit) Wiring harness between HST (female) (5) –
Voltage Max. 1 V
Wiring harness between HST (female) (34) –
Voltage Max. 1 V
FNR (directional)
HST Voltage
lever
Between (34) and F (Forward) 20 – 30 V
32 WA200-6
WA200-6 33
Failure code [DDS5L6] Steering: Low oil pressure (Operation of

emergency steering)
Action code Failure code Steering: Low oil pressure (Operation of emergency steering)
Trouble
E03 DDS5L6 (Machine monitor system)
Contents of
• While engine was running, steering oil pressure sensor signal was “closed”.
trouble
machine monitor • Turns steering oil pressure warning lamp ON.
Problem that
appears on • Steering system does not work except when HST circuit oil pressure is high during travel etc.
machine
Related
• This code is applied to only machine with emergency steering (optional).
information

System is normal.
1 Low steering oil pressure
a Carry out troubleshooting for hydraulic and mechanical systems.
F11 (male) Steering oil pressure Resistance
When oil pressure is
Defective steering oil pres- low
2 sure sensor (switch) (Internal Max. 1 z
(While engine is
defect) stopped)
Between (1) – (2)
normal
Possible causes Min. 1 Mz
(While engine is
and standard running)
value in normal
state Ground fault in wiring har- without turning starting switch ON.
cuit) Between wiring harness L27 (female) (16) – Resis- Min.
F11 (female) (1) and ground tance 1 Mz
troubleshooting.
L27 Steering oil pressure Voltage
4 Defective machine monitor abnormal (low) (below Max. 1 V
Between (16) – 0.5 MPa {5.1 kg/cm2})
ground When oil pressure is
normal (above 0.9 20 – 30 V
MPa {9.2 kg/cm2})
34 WA200-6
WA200-6 35
SEN03741-00

© 2007 KOMATSU
All Rights Reserved
36
SEN03742-00
WA200-6
WA200-6 70001 and up
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.............................. 3
Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................. 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ......................................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault............................................ 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short ........................................................................ 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect.......................................................... 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short ............................................................. 18
Failure code [DLT3KX] Travel speed sensor B: Abnormality ........................................................................ 20
Failure code [DLT4KX] Travel speed sensor A: Abnormality ........................................................................ 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality ................................................................. 26
Failure code [DV00KY] Alarm buzzer: Hot short........................................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ....................................................... 30
WA200-6 1
Failure code [DW26KY] Motor 2 solenoid: Hot short .................................................................................... 32

Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................... 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36
2 WA200-6
Failure code [DF10KA] Travel speed range selector switch:

Disconnection/Ground fault
Action code Failure code Travel speed range selector switch: Disconnection/Ground fault
Trouble
E01 DF10KA (HST controller system)
Contents of • Travel speed range selector switch signal is not input because of disconnection or ground fault in
trouble travel speed range selector switch input signal system.
Action of • Fixes gear to speed range before error occurrence.
controller • If trouble disappears, system resets itself.
• Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on • Gear is not set in selected speed range.
machine • Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information

L03 (female) Switch position Resistance
2nd Max. 1 z
Between (1) – (2)
Other than above Min. 1 Mz
1st Min. 1 Mz
2nd Min. 1 Mz
Between (1) – (3)
3rd Max. 1 z
Defective travel speed range
1 selector switch (Internal 4th Max. 1 z
defect) 4th Max. 1 z
Between (1) – (4)
Possible causes Other than above Min. 1 Mz
and standard
Between (2) – (3) – (Anytime) Min. 1 Mz
value in normal
state Between (2) – (4) – (Anytime) Min. 1 Mz
1st Max. 1 z
2nd Min. 1 Mz
Between (3) – (4)
3rd Min. 1 Mz
4th Max. 1 z
2 selector resistor (Internal Between (1) – (5) 100 z ± 1%
defect) Between (2) – (6) 220 z ± 1%
Between (3) – (7) 330 z ± 1%
Between (4) – (8) 470 z ± 1%
WA200-6 3

Max. 1 z
Max. 1 z
Disconnection in wiring har- L03 (female) (3), L70 (female) (5), (3) tance
ness (Disconnection in wiring Wiring harness between L03 (female) (1) – Resis-
3 Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
L70 (female) (2) (4) tance
and standard Between wiring harness HST (female) (32) – Resis-
value in normal Min. 1 Mz
state
Resis-
Ground fault in wiring har- L03 (female) (3), L70 (female) (5), (3) and Min. 1 Mz
tance
4 ness (Contact with GND cir- ground
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
HST Switch position Voltage
5 Defective HST controller 1st 1.9 – 2.3 V
2nd 2.4 – 2.7 V
Between (39) – (32)
3rd 2.9 – 3.2 V
4th 3.3 – 3.7 V
4 WA200-6
WA200-6 5
Failure code [DF10KB] Travel speed range selector switch: Hot short
Action code Failure code Travel speed range selector switch: Hot short
Trouble
E01 DF10KB (HST controller system)
Contents of • Multiple travel speed range selector switch signal is input because of hot short in travel speed range
trouble selector switch input signal system.
Action of • Fixes gear to speed range before error occurrence.
controller • If trouble disappears, system resets itself.
• Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on • Gear is not set in selected speed range.
machine • Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
• Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information

L03 (female) Switch position Resistance
2nd Max. 1 z
Between (1) – (2)
1st Min. 1 Mz
2nd Min. 1 Mz
Between (1) – (3)
3rd Max. 1 z
1 selector switch (Internal 4th Max. 1 z
defect) 4th Max. 1 z
Between (1) – (4)
1st Max. 1 z
Possible causes 2nd Min. 1 Mz
and standard Between (3) – (4)
value in normal 3rd Min. 1 Mz
state 4th Max. 1 z
2 selector resistor (Internal Between (1) – (5) 100 z ± 1%
defect) Between (2) – (6) 220 z ± 1%
Between (3) – (7) 330 z ± 1%
Between (4) – (8) 470 z ± 1%
Voltage Max. 1 V
3 Between wiring harness HST (female) (39) –
L03 (female) (3), L70 (female) (5), (3) and Voltage Max. 1 V
ground
Voltage Max. 1 V
6 WA200-6

Voltage Max. 1 V
3 circuit) in wiring harness Voltage Max. 1 V
Possible causes
and standard Wiring harness between HST (female) (22) –
Voltage Max. 1 V
value in normal L70 (female) (2) (4) and ground
state HST Switch position Voltage
1st 1.9 – 2.3 V
4 Defective HST controller 2nd 2.4 – 2.7 V
Between (39) – (32)
3rd 2.9 – 3.2 V
4th 3.3 – 3.7 V
WA200-6 7
Failure code [DGH1KX] HST oil temperature sensor: Ground fault

Action code Failure code HST oil temperature sensor: Ground fault
Trouble
E01 DGH1KX (Machine monitor system)
Contents of • HST oil temperature higher than 150°C was detected. (Ground fault in HST oil temperature signal
trouble circuit was detected.)
Action of
• HST oil overheat is not detected.
machine monitor
Problem that
appears on • HST oil temperature gauge indicates maximum.
machine
• Input state from HST oil temperature sensor can be checked with monitoring function.
Related
(Monitoring code: MONITOR PANEL – 04408 – HST OIL TEMP (°C)
information
(Monitoring code: MONITOR PANEL – 04409 – HST OIL TEMP (V)

T10 (male) HST oil temperature Resistance
Defective HST oil tempera-
1 At 25°C 35 – 50 kz
ture sensor (Internal defect) Between (1) – (2)
At 100°C 3.1 – 4.5 kz
Between (1) (2) and
Possible causes – (Anytime) Min. 1 Mz
ground
and standard
state 2 ness (Contact with GND cir-
Min. 1 Mz
T10 (female) (1) and ground tance
3 Defective machine monitor L28 (female) HST oil temperature Voltage
At 25°C 4.4 – 4.6 V
At 100°C 2.1 – 2.3 V
8 WA200-6
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault

Action code Failure code Brake oil temperature sensor: Ground fault
Trouble
E01 DGR2KB (Machine monitor system)
Contents of • Front brake oil temperature above 150°C was detected.
trouble (Ground fault was detected in front brake oil temperature signal circuit.)
Action of
• Brake oil overheat is not detected.
machine monitor
Problem that
• Brake oil temperature gauge indicates upper limit.
appears on
• Brake performance lowers (while system is normal).
machine
• Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)
information (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)
• System resets itself after brake oil temperature reduces below 130°C.

Front brake overheat
1 Check for cause of overheat directly.
(When system is normal)
Defective front brake (axle) F14 (male) Brake oil temperature Resistance
2 oil temperature sensor (Inter- At 25°C 35 – 50 kz
nal defect) Between (1) – (2)
Possible causes At 100°C 3.1 – 4.5 kz
and standard Between (1) (2) and
value in normal – (Anytime) Min. 1 Mz
ground
state
Ground fault in wiring har-
Between wiring harness F14 (female) (1) – Resis-
3 ness (Contact with GND cir- Min. 1 Mz
cuit)
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) – At 25°C 4.4 – 4.6 V
L25 (9) At 100°C 2.1 – 2.3 V
WA200-6 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/

Hot short
Action code Failure code Brake oil temperature sensor: Disconnection/Hot short
Trouble
E01 DGR2KZ (Machine monitor system)
• Disconnection or hot short was detected in front brake oil temperature signal circuit.
Contents of
Reference: Detection is made by sudden change of brake oil temperature or by logic of comparison
trouble
with HST oil temperature.
Action of
machine monitor
Problem that
• Brake oil temperature gauge indicates lower limit.
appears on
• Brake may be broken and brake may not work because of brake oil temperature error.
machine
• Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 30201 – F BRAKE OIL (°C)
information (Monitoring code: MONITOR PANEL – 30204 – F BRAKE OIL (V)
• System resets itself after brake oil temperature increases above 25°C.

Defective front brake (axle)
1 oil temperature sensor (Inter- F14 (male) Brake oil temperature Resistance
nal defect) At 25°C 35 – 50 kz
Between (1) – (2)
At 100°C 3.1 – 4.5 kz
ness (Disconnection in wiring Wiring harness between F14 (female) (1) – Resis-
2 Max. 1 z
Possible causes nector) Wiring harness between F14 (female) (2) – Resis-
value in normal
Hot short (Contact with 24V Between wiring harness F14 (female) (1) –
3 Voltage Max. 1 V
circuit) in wiring harness L28 (female) (7) and ground
Between wiring harness F14 (female) (2) –
Voltage Max. 1 V
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) – At 25°C 4.4 – 4.6 V
L25 (9) At 100°C 2.1 – 2.3 V
10 WA200-6
WA200-6 11
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground

fault
Action code Failure code HST oil pressure sensor: Disconnection/Ground fault
Trouble
E03 DHH1KX (HST controller system)
Contents of • HST oil pressure sensor signal is not input because of disconnection or ground fault in HST oil pres-
trouble sure sensor system (Input voltage is below 0.3 V)
• If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
• Once machine stops, gear is assumed to be in 1st for control.
controller
Problem that
• Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
• If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related • Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))

a Prepare with starting switch OFF, then turn starting twitch ON and
Defective HST oil pressure T11 Voltage
1
sensor (Internal defect)
Between (C) – (A) 0.5 – 4.5 V
Between (B) – (A) 4–6V
Max. 1 z
ness (Disconnection in wiring T11 (female) (C) tance
2
Possible causes nector) Max. 1 z
T11 (female) (A) tance
and standard
value in normal Wiring harness between HST (female) (22) – Resis-
Max. 1 z
state T11 (female) (B) tance
Between wiring harness HST (female) (33) – Resis- Min.
T11 (female) (C) and ground tance 1 Mz
cuit)
Between wiring harness HST (female) (22) – Resis- Min.
T11 (female) (B) and ground tance 1 Mz
troubleshooting.
4 Defective HST controller HST Voltage
Between (33) – (32) 0.5 – 4.5 V
Between (22) – (32) 4–6V
12 WA200-6
WA200-6 13
Failure code [DHH1KY] HST oil pressure sensor: Hot short

Action code Failure code HST oil pressure sensor: Hot short
Trouble
E03 DHH1KY (HST controller system)
Contents of • Abnormal HST oil pressure sensor signal was input because of hot short in HST oil pressure sensor
trouble system (Input voltage was above 4.7 V).
• If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
• Once machine stops, gear is assumed to be in 1st for control.
controller
Problem that
• Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
• If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related • Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))

troubleshooting.
Defective HST oil pressure T11 Voltage
1
sensor (Internal defect)
Between (C) – (A) 0.5 – 4.5 V
Between (B) – (A) 4–6V
Possible causes
and standard
value in normal 2
state circuit) in wiring harness Between wiring harness HST (female) (33) –
Voltage Max. 1 V
T11 (female) (C) and ground
troubleshooting.
Between (33) – (32) 0.5 – 4.5 V
Between (22) – (32) 4–6V
14 WA200-6
WA200-6 15
Failure code [DHTCL6] HST filter clogging sensor: Functional defect

Action code Failure code HST filter clogging sensor: Functional defect
Trouble
E01 DHTCL6 (Machine monitor system)
Contents of
• When engine stopped, HST filter clogging sensor was turned ON (Ground fault was detected).
trouble
Action of
• Turns HST filter clogging caution lamp OFF.
machine monitor
Problem that
appears on • Foreign matter may enter HST hydraulic circuit.
machine
Related • Input state (ON/OFF) of HST filter clogging sensor can be checked with monitoring function.

Defective HST filter clogging without turning starting switch ON.
1
sensor (Internal defect) Resis-
Possible causes Wiring harness between T13 – T14 Min. 1 Mz
tance
and standard
state 2 ness (Contact with GND cir-
Min. 1 Mz
T13 and ground tance
If causes 1 – 2 are not detected, machine monitor may be defective.
16 WA200-6
WA200-6 17
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short

Action code Failure code Fuel level sensor: Disconnection/Hot short
Trouble
E01 DJF1KA (Machine monitor system)
Contents of
• Voltage above 4 V was detected in fuel level sensor signal circuit.
trouble
Action of
machine monitor
Problem that
appears on • Fuel level gauge does not indicated normally (but keeps indicating “empty”).
machine
• Input signal from fuel level sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL – 04200 – FUEL SENSOR (V))
information (Monitoring code: MONITOR PANEL – 04202 – FUEL SENSOR (%))

Defective fuel level sensor R21 (male) Fuel level Resistance

1
(Internal defect) When full 7 – 11 z
Between (1) – (2) When 1/2 25 – 35 z
When empty 60 – 95 z
ness (Disconnection in wiring Wiring harness between L28 (female) (1) – Resis-
2 Max. 1 z
or defective contact in con- R21 (female) (1) tance
Possible causes nector) Wiring harness between L26 (female) (6) – Resis-
Max. 1 z
and standard R21 (female) (2) tance
state and carry out troubleshooting.
3 R21 (female) (1) and ground Voltage Max. 2 V
(Value is upper limit when empty.)
Voltage Max. 1 V
R21 (female) (2)
L26, L28 Fuel level Voltage
When full 0.1 – 0.4 V
Between L28 (1) –
When 1/2 0.7 – 1.0 V
L26 (6)
When empty 1.4 – 2.0 V
18 WA200-6
WA200-6 19
Failure code [DLT3KX] Travel speed sensor B: Abnormality

Action code Failure code Travel speed sensor B: Abnormality
Trouble
E03 DLT3KX (HST controller system)
Contents of • While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor B was
trouble lost.
Action of • Recognizes travel speed by input signal of travel speed sensor A.
Problem that
appears on • None in particular.
machine
Related • If failure code [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simulta-
information neously, see causes 6 and after.

a Prepare with starting switch OFF, then start engine (but do not
travel) and carry out troubleshooting.
T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sen- Between (2) – ground Max. 1 V
1
sor (Internal defect) a Prepare with starting switch OFF, then start engine, travel at con-
stant speed, and carry out troubleshooting.
T09 Voltage
Below 1 V – Above 4 V
Between (4) – (2)
(Changes at regular intervals)
2
nector) Max. 1 z
T09 (female) (4) tance
Possible causes
value in normal
state Between wiring harness HST (female) (36) – Resis-
Min. 1 Mz
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
– Above
Between wiring harness HST (36) – T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
a Prepare with starting switch OFF, then start engine, travel at con-
Below 1 V
Hot short (Contact with 24V – Above
4
circuit) in wiring harness Between wiring harness HST (36) – T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
20 WA200-6

troubleshooting without traveling.
HST Voltage
Possible causes Between (22) – (32) 4.7 – 5.3 V
and standard
value in normal Between (32) – ground Max. 1 V
state a Prepare with starting switch OFF, then start engine, travel at con-
HST Voltage
Between (36) – (32)
WA200-6 21
a When [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously
Contents of • While machine was traveling at speed above about 4 km/h, input signals of travel speed sensors A
trouble and B were lost.
• Keeps outputs to HST motor 1, HST motor 2 and clutch at values before trouble.
Action of
• Keeps output values after clutch is engaged or disengaged completely, if clutch is being controlled.
controller
Problem that
• Travel speed does not increase or traction force is insufficient.
appears on
• Machine monitor indicates 0 km/h as travel speed.
machine
• If trouble occurs while machine is stopped or traveling at low speed (below about 4 km/h), error is not
Related turned ON.
information • In above case, machine monitor indicates 0 km/h as travel speed and actual travel speed is limited to
4 – 7 km/h.

T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sen- a Prepare with starting switch OFF, then start engine, travel at con-
6
sor (Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Between (3) – (2)
Between (4) – (2)
Possible causes Wiring harness between HST (female) (22) – Resis-

Max. 1 z
and standard Disconnection in wiring har- T09 (female) (1) tance
value in normal ness (Disconnection in wiring Wiring harness between HST (female) (32) – Resis-
7 Max. 1 z
state or defective contact in con- T09 (female) (2) tance
nector) Wiring harness between HST (female) (26) – Resis-
Max. 1 z
Max. 1 z
Between wiring harness HST (female) (22) – Resis-
Ground fault in wiring har- Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
9
circuit) in wiring harness Between wiring harness HST (32) – T09 (2)
Voltage Max. 1 V
and ground
22 WA200-6

HST Voltage
Between (22) – (32) 4.7 – 5.3 V
Possible causes
and standard
value in normal 10 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
state stant speed, and carry out troubleshooting.
HST Voltage
Between (26) – (32)
Between (36) – (32)
WA200-6 23
Failure code [DLT4KX] Travel speed sensor A: Abnormality

Action code Failure code Travel speed sensor A: Abnormality
Trouble
E03 DLT4KX (HST controller system)
Contents of • While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor A was
trouble lost.
Action of • Recognizes travel speed by input signal of travel speed sensor B.
Problem that
appears on • None in particular.
machine
Related • If failure code [DLT4KX] and [DLT3KX] (Travel speed sensor B: Abnormality) are turned ON simulta-
information neously, see [DLT3KX], causes 6 and after.

T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sen- Between (2) – ground Max. 1 V
1
sor (Internal defect) a Prepare with starting switch OFF, then start engine, travel at con-
T09 Voltage
Between (3) – (2)
2
nector) Max. 1 z
Possible causes
value in normal
state Between wiring harness HST (female) (26) – Resis-
Min. 1 Mz
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
– Above
Between wiring harness HST (26) – T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
Below 1 V
Hot short (Contact with 24V – Above
4
circuit) in wiring harness Between wiring harness HST (26) – T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
24 WA200-6

HST Voltage
Possible causes Between (22) – (32) 4.7 – 5.3 V
and standard
value in normal Between (32) – ground Max. 1 V
state a Prepare with starting switch OFF, then start engine, travel at con-
HST Voltage
Between (26) – (32)
WA200-6 25
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality

Action code Failure code Travel speed sensor A & B: Abnormality
Trouble
E03 DLT4LC (HST controller system)
Contents of
• Difference between values sensed by travel speed sensors A and B during travel is large.
trouble
controller • None in particular other than above (Uses higher value normally).
Problem that
appears on
machine
Related
• Even trouble disappears, system does not reset itself until engine is started again.
information

travel) and carry out troubleshooting without traveling.
T09 Voltage
Between (1) – (2) 4.7 – 5.3 V
Defective travel speed sen- a Prepare with starting switch OFF, then start engine, travel at con-
1
sor (Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Between (3) – (2)
Between (4) – (2)
2 Max. 1 z
or defective contact in con- T09 (female) (3) tance
Possible causes
nector) Wiring harness between HST (female) (36) – Resis-
value in normal T09 (female) (4) tance
3 ness (Contact with GND cir- Min. 1 Mz
cuit)
Min. 1 Mz
Below 1 V
– Above
Between wiring harness HST (female) (26) – 4V
Voltage
T09 (female) (3) and ground (Changes
Hot short (Contact with 24V at regular
4
circuit) in wiring harness intervals)
Below 1 V
– Above
Between wiring harness HST (female) (36) – 4V
Voltage
T09 (female) (4) (Changes
at regular
intervals)
26 WA200-6

HST Voltage
Between (22) – (32) 4.7 – 5.3 V
Possible causes
and standard
value in normal 5 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
state stant speed, and carry out troubleshooting.
HST Voltage
Between (26) – (32)
Between (36) – (32)
WA200-6 27
Failure code [DV00KY] Alarm buzzer: Hot short

Action code Failure code Alarm buzzer: Hot short
Trouble
E01 DV00KY (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power source.
trouble
• Stops alarm buzzer output.
Action of • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
machine monitor • If trouble occurs while backup alarm/lamp is in operation, backup alarm/lamp output is turned OFF.
• If trouble occurs while ECSS is in operation, ECSS output is turned OFF.
Problem that • Alarm buzzer does not sound.
appears on • Backup alarm/lamp may not operate.
machine • ECSS may not operate.
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function.
• Output state (ON/OFF) to backup alarm/lamp relay can be checked with monitoring function.
Related
(Code: MONITOR PANEL – 40952 – D-OUT-2)
information
• Output state (ON/OFF) to ECSS relay can be checked with monitoring function.
(Code: MONITOR PANEL – 40952 – D-OUT-3)

1
(Contact with 24V circuit) Wiring harness between L24 (female) (14) –
Voltage Max. 1 V
L46 (female) (2) and chassis ground
Possible causes and carry out troubleshooting.
and standard • Remove the buzzer, then connect +24 V to L46 (male) (1) and
value in normal Defective alarm buzzer GND to L46 (male) (2).
state 2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
• When above 1 and 2 are normal, failure on the machine monitor
3 Defective machine monitor can be suspected. (Since trouble is in system, troubleshooting
cannot be carried out.)
28 WA200-6
WA200-6 29
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault

Action code Failure code Motor 2 solenoid: Disconnection/Ground fault
Trouble
E01 DW26KA (HST controller system)
Contents of • Motor 2 cannot be controlled because of disconnection or ground fault in motor 2 solenoid relay out-
trouble put system.
• Keeps output to motor 2 solenoid relay turned OFF (If there is ground fault, output cannot be turned
Action of
OFF actually).
controller
Problem that • When there is disconnection: Travel speed is not limited and maximum speed is equivalent to 4th
appears on gear speed in 3rd speed range.
machine • When there is ground fault: Travel speed is set equivalent to 3rd gear speed in 4th speed range.
• Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
Related
(Monitoring code: HST – 40980 – D-OUT-16)
information
• Method of reproducing failure code: Travel at speed above about 11 km/h in 4th speed range.

Replace motor 2 normal defective
solenoid relay (L103)
Defective motor 2 solenoid with another relay. Condition does not Relay (L103) is
1
relay (Internal defect) become normal normal
Resis- 200 –
tance 400 z
troubleshooting.
2 holding relay (Internal short relay. become normal. normal.
circuit)
value in normal Resis- 200 –
tance 400 z
3 Max. 1 z
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, travel, and
HST Condition Voltage
5 Defective HST controller Stopped Max. 1 V
Between (27) – Speed range: 4th
ground Travel speed: Above 20 – 30 V
11 km/h
30 WA200-6
WA200-6 31
Failure code [DW26KY] Motor 2 solenoid: Hot short

Action code Failure code Motor 2 solenoid: Hot short
Trouble
E01 DW26KY (HST controller system)
Contents of
• Motor 2 solenoid cannot be operated because of hot short in motor 2 solenoid relay output system.
trouble
Action of • Keeps output to motor 2 solenoid relay turned OFF.
Problem that
• When the gear is shifted to 3rd, travel speed is not limited and maximum travel speed is equivalent to
appears on
4th-gear speed.
machine
Related • Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
information (Monitoring code: HST – 40980 – D-OUT-16)

Replace motor 2 normal defective
Defective motor 2 solenoid with another relay. Condition does not Relay (L103) is
1
and standard Resis- 200 –
value in normal tance 400 z
Ground fault in wiring har- and carry out troubleshooting.
2 ness (Contact with GND cir- Voltage
cuit) Wiring harness between HST (female) (27) –
(When Max. 1 V
L103 (female) (2)
stopped)
HST Voltage
32 WA200-6
WA200-6 33
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short

Action code Failure code Fan reverse solenoid circuit: Hot short
Trouble
E01 DW7BKY (HST controller system)
Contents of • Abnormal voltage was generated because of hot short in fan reverse solenoid relay output system
trouble when fan reverse solenoid relay output was turned ON.
Action of • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Problem that
appears on • Fan does not reverse (Manual reverse function and automatic reverse function do not work).
machine
• Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related (Monitoring code: HST – 40980 – D-OUT-17)
information • Method of reproducing failure code: Start engine, wait for at least 30 seconds, and then press man-
ual reverse switch.

Replace fan reverse normal defective
Defective fan reverse sole- with another relay. Condition does not Relay (L104) is
1
noid relay (Internal defect) become normal normal
Possible causes Resis- 200 –

and standard tance 400 z
value in normal a Prepare with starting switch OFF, then start engine and carry out
state troubleshooting.
Hot short (Contact with 24V Voltage (In fan for-
2 20 – 30 V
circuit) in wiring harness Wiring harness between HST ward mode)
(female) (37) – L104 (female) (2) Voltage (In fan
Max. 1 V
reverse mode)
troubleshooting.
3 Defective HST controller HST Fan condition Voltage
Between (37) – In fan forward mode 20 – 30 V
ground In fan reverse mode Max. 1 V
34 WA200-6
WA200-6 35
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/

Ground fault
Action code Failure code Fan reverse solenoid circuit: Disconnection/Ground fault
Trouble
E01 DW7BKZ (HST controller system)
Contents of • Fan reverse solenoid relay cannot be controlled because of disconnection or ground fault in fan
trouble reverse solenoid relay output system.
Action of • Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Problem that • Manual reverse function and automatic reverse function do not work.
appears on • Fan always turns forward (When there is disconnection).
machine • Fan always turns in reverse (When there is ground fault).
• Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related
information

Replace fan reverse normal defective
Defective fan reverse sole- with another relay. Condition does not Relay (L104) is
1
noid relay (Internal defect) become normal normal
Resis- 200 –
tance 400 z
troubleshooting.
2 holding relay (Internal short relay. become normal. normal.
Possible causes circuit)
state Resis- 200 –
tance 400 z
3 Max. 1 z
Max. 1 z
Min. 1 Mz
troubleshooting.
5 Defective HST controller HST Fan condition Voltage
Between (37) – In fan forward mode 20 – 30 V
ground In fan reverse mode Max. 1 V
36 WA200-6
WA200-6 37
SEN03742-00

© 2007 KOMATSU
All Rights Reserved
38
SEN03743-00
WA200-6
WA200-6 70001 and up
Failure code [DX16KA] Fan EPC solenoid: Disconnection............................................................................. 3
Failure code [DX16KB] Fan EPC solenoid: Ground fault................................................................................ 4
Failure code [DX16KY] Fan EPC solenoid: Hot short..................................................................................... 5
Failure code [DX19KA] Motor 1 solenoid: Disconnection ............................................................................... 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault .................................................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short ..................................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....................................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault.......................................................................... 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short............................................................................... 16
Failure code [DXH7KB] Reverse solenoid: Ground fault .............................................................................. 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short ............................................................ 20
Failure code [DXH8KB] Forward solenoid: Ground fault .............................................................................. 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short ............................................................ 24
Failure code [J141N1] Steering pump: Overrun alarm.................................................................................. 26
WA200-6 1
Failure code [M100N1] HST pump: Overrun alarm....................................................................................... 26

Failure code [M400N1] Motor 1: Overrun alarm............................................................................................ 27
2 WA200-6
Failure code [DX16KA] Fan EPC solenoid: Disconnection 1

Action code Failure code Fan EPC solenoid: Disconnection
Trouble
E01 DX16KA (HST controller system)
Contents of • Since the fan EPC solenoid system is disconnected, no current flows when the fan EPC solenoid
trouble output is ON.
Action of
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
controller
Problem that
appears on • The fan speed is set to the maximum.
machine
• If [DX16KY] is displayed, carry out troubleshooting for it first.
Related • The output state (current) to the fan EPC solenoid can be checked with the monitoring function
information (Code: HST – 41400 – FAN EPC DIR).

Defective fan EPC solenoid without turning starting switch ON.
1
(Internal disconnection) R29 (male) Resistance
Between (1) – (2) 5 – 10 z
Possible causes
state ness Wiring harness between HST (female) (40) – Resis-
2 Max. 1 z
(Disconnection or defective R29 (female) (2) tance
contact in connector) Wiring harness between HST (female) (29) – Resis-
Max. 1 z
R29 (female) (1) tance
• If causes 1 – 2 are not detected, HST controller may be defective.
WA200-6 3
Failure code [DX16KB] Fan EPC solenoid: Ground fault 1

Action code Failure code Fan EPC solenoid: Ground fault
Trouble
E01 DX16KB (HST controller system)
Contents of • Since the fan EPC solenoid system is shorted, abnormal current flows when the fan EPC solenoid
trouble output is ON.
Action of • Turns the output to the fan EPC solenoid OFF.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
• The output state (current) to the fan EPC solenoid can be checked with the monitoring function
Related
(Code: HST – 41400 – FAN EPC DIR).
information

Defective fan EPC solenoid R29 (male) Resistance
1
(Internal short circuit)
Possible causes Between (1) – (2) 5 – 10 z
and standard Between (1), (2) and ground Min. 1 Mz
value in normal
state Grounding fault in wiring har- without turning starting switch ON.
2 ness
(Contact with ground circuit) Wiring harness between HST (female) (29) – Resis-
Min. 1 Mz
R29 (female) (1) and ground tance
4 WA200-6
Failure code [DX16KY] Fan EPC solenoid: Hot short 1

Action code Failure code Fan EPC solenoid: Hot short
Trouble
E01 DX16KY (HST controller system)
Contents of • Since the fan EPC solenoid system is shorted with the power source, abnormal voltage is applied
trouble when the fan EPC solenoid output is OFF.
Action of • Turns the output to the fan EPC solenoid OFF.
controller • If problem is removed, system is returned to normal operating state.
Problem that
appears on • The fan speed is minimized.
machine
• The output state (current) to the fan EPC solenoid can be checked with the monitoring function
Related
(Code: HST – 41400 – FAN EPC DIR).
information

Defective fan EPC solenoid R29 (male) Resistance
1
(Internal short circuit)
and standard Between (1), (2) and ground Min. 1 Mz
value in normal
state
2
(Contact with 24V circuit) Wiring harness between HST (female) (29) –
Voltage Max. 1 V
R29 (female) (1) and ground
WA200-6 5
Failure code [DX19KA] Motor 1 solenoid: Disconnection 1

Action code Failure code Motor 1 solenoid: Disconnection
Trouble
Contents of • Disconnection was detected in motor 1 solenoid circuit.
trouble (Difference between output command value and actual current is large.)
Action of
controller
• Traction force is decreased.
Problem that
appears on
machine
denly.
Related
information
• If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.

Defective motor 1 solenoid T06 (male) Resistance
1
(Internal defect)
Between (1) – (2) 15 – 30 z
Between (1), (2) – ground Min. 1 Mz
Max. 1 z
ness (Disconnection in wiring T06 (female) (1) tance
2
or defective contact in con- Wiring harness between T06 (female) (2) – Resis-
nector) Max. 1 z
Possible causes
and standard Wiring harness between L111 (female) (5) – Resis-
Max. 1 z
value in normal HST (female) (40) tance
Replace HST safety normal defective
relay (L111) with
another relay Condition does not Relay (L111) is
Defective HST safety relay become normal normal
3
(L111) (Internal defect)
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between Resis-
Max. 1 z
Between L111 (male) (1) – (2). tance
(3) – (5) Apply no voltage Resis-
Min. 1 Mz
between (1) – (2). tance
6 WA200-6
WA200-6 7
Failure code [DX19KB] Motor 1 solenoid: Ground fault 1

Action code Failure code Motor 1 solenoid: Ground fault
Trouble
Contents of
• Ground fault was detected in motor 1 solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.

1
(Internal defect)
and standard Between (1), (2) – ground Min. 1 Mz
value in normal
Min. 1 Mz
Defective HST safety relay • If causes 1 – 2 are not detected, HST controller may be defective.
3
(L111) (Internal defect) (Since trouble is in system, troubleshooting cannot be carried out.)
8 WA200-6
WA200-6 9
Failure code [DX19KY] Motor 1 solenoid: Hot short 1

Action code Failure code Motor 1 solenoid: Hot short
Trouble
Contents of
• Hot short was detected in motor 1 solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.
Related HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
information Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA)
• [DX19KA], [DX20KA] or [DX20KY] may be also displayed, depending on condition when error was
detected.

1
(Internal defect)
Between (1) – (2) 15 – 30 z
Possible causes
and standard Between wiring harness T06 (female) (1) –
Voltage Max. 1 V
value in normal HST (female) (19)
state Wiring harness between T06 (female) (2) –
Hot short (Contact with 24V Voltage Max. 1 V
2 L111 (female) (3) and ground.
(Check with traction control OFF and machine stopped.)
Voltage 10 – 15 V
T06 (female) (1)
Defective HST safety relay • If causes 1 – 2 are not detected, HST controller may be defective.
3
(L111) (Internal defect) (Since trouble is in system, troubleshooting cannot be carried out.)
10 WA200-6
WA200-6 11
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 1

Action code Failure code Clutch EPC solenoid: Disconnection
Trouble
• Disconnection was detected in clutch EPC solenoid circuit.
Contents of
(When output command was above 250 mA, difference between command value and sensed cur-
trouble
rent exceeded 200 mA.)
Action of
controller
Problem that
appears on
machine
denly.
Related
information
• If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.

Defective clutch EPC sole- T05 (male) Resistance
1
noid (Internal defect)
Between (1) – (2) 5 – 15 z
Max. 1 z
ness (Disconnection in wiring T05 (female) (1) tance
2
or defective contact in con- Wiring harness between T05 (female) (2) – Resis-
nector) Max. 1 z
Possible causes
and standard Wiring harness between L111 (female) (5) – Resis-
Max. 1 z
value in normal HST (female) (40) tance
Replace HST safety normal defective
relay (L111) with
another relay Condition does not Relay (L111) is
Defective HST safety relay become normal normal
3
(L111) (Internal defect)
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between Resis-
Max. 1 z
Between L111 (male) (1) – (2). tance
(3) – (5) Apply no voltage Resis-
Min. 1 Mz
between (1) – (2). tance
12 WA200-6
WA200-6 13
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 1

Action code Failure code Clutch EPC solenoid: Ground fault
Trouble
Contents of
• Ground fault was detected in clutch EPC solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.

1
and standard Between (1), (2) – ground Min. 1 Mz
value in normal
Min. 1 Mz
14 WA200-6
WA200-6 15
Failure code [DX20KY] Clutch EPC solenoid: Hot short 1

Action code Failure code Clutch EPC solenoid: Hot short
Trouble
Contents of
• Hot short was detected in clutch EPC solenoid circuit.
trouble
Action of
controller
Problem that
appears on
machine
denly.
Related HST safety relay output: HST – 40979 – D_OUT_15 (ON/OFF)
information Clutch EPC solenoid output: HST – 80100 – CLUTCH SOL DIR (mA)
• [DX19KA], [DX19KY] or [DX20KA] may be also displayed, depending on condition when error was
detected.

1
Between (1) – (2) 5 – 15 z
value in normal
state Voltage Max. 1 V
Hot short (Contact with 24V T05 (female) (1) and ground
2
circuit) in wiring harness Between wiring harness L111 (female) (3) –
Voltage Max. 1 V
T05 (female) (2)
Voltage Max. 1 V
T05 (female) (1) and ground
16 WA200-6
WA200-6 17
Failure code [DXH7KB] Reverse solenoid: Ground fault 1

Action code Failure code Reverse solenoid: Ground fault
Trouble
E03 DXH7KB (HST controller system)
Contents of
• Reverse solenoid is not turned ON.
trouble
Action of • Turns output to reverse solenoid OFF.
Problem that
appears on • Machine does not travel in reverse.
machine
• Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective reverse solenoid T01 (male) Resistance
1
(Internal defect)
Between (3) – (4) 15 – 30 z
(Internal defect)
Between T01B (male) (1) – (2) No continuity
troubleshooting.
Possible causes Replace FR pressure normal defective
and standard select relay (L101)
value in normal Defective FR pressure select with another relay Condition does not Relay (L101) is
3
state relay (Internal defect) become normal normal
Resis- 200 –
tance 400 z
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, release park-
ing brake, set directional lever in R position, and carry out trouble-
5 Defective HST controller shooting.
HST Voltage
18 WA200-6
WA200-6 19
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 1

Action code Failure code Reverse solenoid: Disconnection/Hot short
Trouble
E03 DXH7KZ (HST controller system)
• Reverse solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
• Reverse solenoid cannot be turned OFF (Where there is hot short).
Action of • Turns output to reverse solenoid OFF.
Problem that • Machine does not travel in reverse (when there is disconnection).
appears on • Machine may start in reverse suddenly (when there is hot short).
machine • Gear is not set in neutral (when there is hot short).
• Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective reverse solenoid T01 (male) Resistance
1
(Internal defect)
Between (3) – (4) 15 – 30 z
(Internal defect)
Between T01B (male) (2) – (1) No continuity
Replace FR pressure normal defective
select relay (L101)
Defective FR pressure select with another relay Condition does not Relay (L101) is
3
value in normal Resis- 200 –
tance 400 z
4 Max. 1 z
nector) Wiring harness between T01 (female) (4) – Resis-
Max. 1 z
ground tance
5
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
Directional lever
position
Between (20) – R (Reverse) 20 – 30 V
20 WA200-6
WA200-6 21
Failure code [DXH8KB] Forward solenoid: Ground fault 1

Action code Failure code Forward solenoid: Ground fault
Trouble
E03 DXH8KB (HST controller system)
Contents of
• Forward solenoid is not turned ON.
trouble
Action of • Turns output to forward solenoid OFF.
Problem that
appears on • Machine does not travel forward.
machine
• Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective forward solenoid T01 (male) Resistance
1
(Internal defect)
Between (1) – (2) 15 – 30 z
Possible causes 2 (See Testing and adjusting, “Test procedure for diode”.)
(Internal defect)
and standard
value in normal Between T01A (male) (1) – (2) No continuity
Min. 1 Mz
ing brake, set directional lever in F position, and carry out trouble-
4 Defective HST controller shooting.
HST Voltage
22 WA200-6
WA200-6 23
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 1

Action code Failure code Forward solenoid: Disconnection/Hot short
Trouble
E03 DXH8KZ (HST controller system)
• Forward solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
• Forward solenoid cannot be turned OFF (Where there is hot short).
Action of • Turns output to forward solenoid OFF.
Problem that • Machine does not travel forward (when there is disconnection).
appears on • Machine may start forward suddenly (when there is hot short).
machine • Gear is not set in neutral (when there is hot short).
• Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective forward solenoid T01 (male) Resistance
1
(Internal defect)
Between (1) – (2) 15 – 30 z
(Internal defect)
Between T01A (male) (1) – (2) No continuity
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between HST (female) (10) – Resis-
value in normal 3 Max. 1 z
state nector) Wiring harness between T01 (female) (2) – Resis-
Max. 1 z
ground tance
4
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
Directional lever
position
Between (10) – F (Forward) 20 – 30 V
24 WA200-6
WA200-6 25
Failure code [J141N1] Steering pump: Overrun alarm 1

Action code Failure code Steering pump: Overrun alarm
Trouble
E02 J141N1 (HST controller system)
Contents of
• Steering pump speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on • Steering pump may be broken (If it is broken, machine may not steer).
machine
Related • Advance alarm is turned ON before this code is displayed.
information • If steering pump speed decreases below alarm reset value, system resets itself.

and standard
value in normal a Give operator instructions to use engine in range where alarm is
1 Steering pump overrun
state not turned ON.
Failure code [M100N1] HST pump: Overrun alarm 1

Action code Failure code HST pump: Overrun alarm
Trouble
E02 M100N1 (HST controller system)
Contents of
• HST pump speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on • HST pump may be broken (If it is broken, machine cannot travel).
machine
information • If HST pump speed decreases below alarm reset value, system resets itself.

and standard
1 HST pump overrun
26 WA200-6
Failure code [M400N1] Motor 1: Overrun alarm 1

Action code Failure code Motor 1: Overrun alarm
Trouble
E02 M400N1 (HST controller system)
Contents of
• HST motor 1 speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on • HST motor 1 may be broken (If it is broken, machine cannot travel).
machine
information • If HST motor 1 speed decreases below alarm reset value, system resets itself.

and standard
1 HST motor 1 overrun
WA200-6 27
SEN03743-00

© 2007 KOMATSU
All Rights Reserved
28
SEN03744-00
WA200-6
WA200-6 70001 and up
Troubleshooting of electrical system
(E-mode)
E-1 Engine does not start ............................................................................................................................... 3
E-2 Preheater does not operate normally ..................................................................................................... 10
E-3 Defective boom kick-out function and cancellation ................................................................................ 14
E-4 Defective bucket positioner function and cancellation............................................................................ 18
E-5 Defective lift arm FLOATING holding function and cancellation............................................................. 22
E-6 Travel direction selection system does not function ............................................................................... 26
E-7 Wiper does not operate .......................................................................................................................... 30
E-8 Windshield washer does not operate ..................................................................................................... 34
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off.......................................................... 38
E-10 Working lamp does not light up or go off .............................................................................................. 46
E-11 Turn signal lamp and hazard lamp do not light up or go off.................................................................. 51
E-12 Brake lamp does not light or it keeps lighting up .................................................................................. 58
E-13 Backup lamp does not light or it keeps lighting up ............................................................................... 60
E-14 Backup alarm does not sound or it keeps sounding............................................................................. 63
WA200-6 1
E-15 Horn does not sound or it keeps sounding ........................................................................................... 66

E-16 Alarm buzzer does not sound or it keeps sounding.............................................................................. 68
E-17 Air conditioner does not operate or stop............................................................................................... 70
E-18 The KOMTRAX system does not work properly................................................................................... 73
2 WA200-6
E-1 Engine does not start 1

Contents of
trouble
• Before starting troubleshooting, check the following.
a. Directional lever is in N (Neutral).
b. Directional switch is in N (Neutral).
c. Starting of engine is prohibited by function of KOMTRAX.
d. Battery cable is not disconnected from battery.
Related • The engine does not start, because the starting motor does not run due to troubles in the starting
information motor system and starting switch terminal C signal system.
• Check that fuse is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-2).
• If failure code is indicated, carry out troubleshooting for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
The battery relay can be judged normal if operating sounds are audible
Defective battery relay
2 when the starting switch is operated.
(Internal trouble)
• Starting switch operation in the order of OFF o ON o OFF
If the fuse is burn, the circuit probably has a grounding fault, etc. (See
3 Defective fuse
cause 18.)
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch START and carry out troubleshooting
Starting motor Voltage
Between terminals B (E30)
Defective starting motor Power supply input 20 – 30 V
4 and ground
(Internal trouble)
Between terminals C (E21)
Starting input 20 – 30 V
and ground
If the starting motor does not run even if power supply input, battery
Possible
input and starting input is normal, the starting motor is defective.
causes and
standard value a Prepare with starting switch OFF, then turn starting switch ON and
in normal state Defective alternator carry out troubleshooting.
5
(Internal trouble) Wiring harness between alternator terminal R
Voltage Max. 1 V
E02 (female) (1) – ground
a Prepare with starting switch OFF, then carry out troubleshooting with
starting OFF and START each.
L02 (male) Position of switch Resistance
Defective starting switch OFF Min. 1 Mz
6
START Max. 1 z
Between (1) and (2) OFF Min. 1 Mz
Between (1) and (4) ON Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and
Defective multifunction
lever switch FNR (directional)
7 MLT (male) Voltage
(Internal disconnection or lever
short circuit) N (Neutral). 20 – 30 V
Between (1) and (3)
Other than above Max. 1 V
WA200-6 3

a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
D21 (male) Diode range Continuity
Defective diodes (D21, Measure at (2) in
Between (2) and (1) Continue
D22) (Internal trouble) diode range.
8
a Only when both diodes a Prepare with starting switch OFF, then carry out troubleshooting with-
are detective out turning starting switch ON.
Measure at (2) in
diode range.
Defective diodes (D01)
9 Measure at (5) in
(Internal trouble) Between (5) and (1) Continue
diode range.
Measure at (6) in
diode range.
Possible
causes and Defective diodes (D03)
standard value 10 (Internal trouble) Between (7) and (3)
Measure at (7) in
Continue
in normal state diode range.
Measure at (8) in
diode range.
Defective diode (D10)
11 D10 (male) Diode range Continuity
(Internal defect)
Measure on (2) side
Between (2) – (1) Continuity is secured
in diode range
a Prepare with starting switch OFF (with wiring harness connected),
then carry out troubleshooting without turning starting switch ON.
Starting motor safety relay Voltage
Between B-terminal
Power supply input 20 – 30 V
E20 – E-terminal
Defective starting motor Between R-terminal E01
Charge input Max. 1 V
12 safety relay (male) (2) – E-terminal
(Internal defect) Between S-terminal E01
Starting input 20 – 30 V
(male) (1) – E-terminal
Between C-terminal
Output 20 – 30 V
E19 – E-terminal
If power supply input and starting input are normal but output voltage is
low, starting motor safety relay is defective.
4 WA200-6

Between (1) and (2) 200 – 400 z
a Check neutral safety relay unit.
Neutral safety relay
Defective neutral safety (L106)
13 relay (L106) When 24 V is applied
(Internal trouble) Max. 1 z
(When relay is "ON")
Between (3) – (5)
Other than above
Min. 1 Mz
(When relay is "OFF")
a Prepare with starting switch OFF, then turn starting switch to START
When neutral safety relay (L106) is replaced with a relay of the same
type, if the condition becomes normal, the neutral safety relay is defec-
tive.
L107 (male), L108 (male) Resistance
Possible
Between (1) and (2) 200 – 400 z
causes and
standard value a Prepare with starting switch OFF.
in normal state a Check engine control cut-out relay unit.
Engine control cut-out
Defective engine control relay (L107), (L108)
14 cut-out relays (L107, When 24 V is applied
L108) (Internal defect) Max. 1 z
Between (3) – (5)
Other than above
Min. 1 Mz
When engine control cut-out relay (L107, L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine control
cut-out relay is defective.
Between (1) and (2) 200 – 400 z
Defective KOMTRAX
15 engine cut-out relay (L79) Between (3) and (6) Min. 1 Mz
(Internal trouble) a Prepare with starting switch OFF, then turn starting switch to START
When KOMTRAX engine cut-out relay (L79) is replaced with a relay of
the same type, if the condition becomes normal, the KOMTRAX engine
cut-out relay is defective.
WA200-6 5

Between (1) – (2) 200 – 400 z
a Check VIS power supply holding relay
VIS power supply
Defective VIS power sup- holding relay (L102)
16 ply holding relay (L102) When 24 V is applied
(Internal defect) Max. 1 z
Between (3) – (5)
Other than above
Min. 1 Mz
When VIS power supply holding relay (L102) is replaced with another
relay, if condition becomes normal, VIS power supply holding relay is
defective.
Wiring harness between battery relay R04 – Resis-
Max. 1 z
starting motor terminal B (E30) tance
Between starting motor B-terminal E30 – starting Resis-
Max. 1 z
Possible motor safety relay B-terminal E20 tance
causes and Between starting motor C-terminal E21 – starting Resis-
standard value Max. 1 z
motor safety relay C-terminal E19 tance
in normal state
Wiring harness between L02 (female) (3) – L79 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (3) tance
Wiring harness between L106 (female) (5) – E01 Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring Wiring harness between L15 (female) (3) – L106 Resis-
harness Max. 1 z
(female) (1) tance
17 (Disconnection in wiring
harness or defective con- Wiring harness between L106 (female) (2) – Resis-
Max. 1 z
tact) MLT (female) (3), L63 (female) (3) tance
Wiring harness between MLT (female) (1), L63 Resis-
Max. 1 z
(female) (4) – ground tance
Max. 1 z
(female) (1), L108 (female) (1) tance
Wiring harness between L02 (female) (4) – EC2 Resis-
Max. 1 z
(female) (39) tance
Wiring harness between L107 (female) (2), L108 Resis-
Max. 1 z
(female) (2) – EC2 (female) (33) tance
Wiring harness between fuse No. 4 of fuse box Resis-
Max. 1 z
(FS1) – L107 (female) (3), L108 (female) (3) tance
Max. 1 z
(female) (5) – EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), (2) – Resis-
Max. 1 z
ground tance
6 WA200-6

Wiring harness between battery relay R04 – Resis-
Min. 1 Mz
starting motor terminal B (E30) and ground tance
Between wiring harness starting motor B-termi-
Resis-
nal E30 – starting motor safety relay B-terminal Min. 1 Mz
tance
E20 and ground
Between wiring harness starting motor C-termi-
Resis-
nal E21 – starting motor safety relay C-terminal Min. 1 Mz
tance
E19 and ground
Min. 1 Mz
(female) (3), – circuit branch end and ground tance
Min. 1 Mz
(female) (3) and ground tance
Wiring harness between L106 (female) (5) – E01 Resis-
Ground fault in wiring har- (female) (1) and ground Min. 1 Mz
tance
ness
18 Between wiring harness L02 (female) (2) – L107 Resis-
(Contact with ground cir- Min. 1 Mz
(female) (1), L108 (female) (1) and ground tance
cuit)
Between wiring harness L02 (female) (4) – EC2 Resis-
Min. 1 Mz
(female) (39) and ground tance
Between wiring harness L15 (female) (3) – L106 Resis-
Min. 1 Mz
Possible (female) (1) and ground tance
causes and Between wiring harness L102 (female) (3) – L15 Resis-
Min. 1 Mz
standard value (female) (1) and ground tance
in normal state Between wiring harness fuse box (FS1) No. 3 Resis-
Min. 1 Mz
fuse – L102 (female) (5) and ground tance
Min. 1 Mz
(female) (2) – EC2 (female) (33) and ground tance
Wiring harness between fuse No. 4 of fuse box
Resis-
(FS1) – L107 (female) (3), L108 (female) (3) and Min. 1 Mz
tance
ground
Min. 1 Mz
(female) (5) – EC3 (female) (3), (4) and ground tance
Wiring harness between L107 (female) (2), L108
Hot short in wiring harness (female) (2) – EC2 (female) (33), alternator ter-
19
(Contact with 24V circuit) minal R E02 (female) (1) – E01 (female) (2), –
Voltage Max. 1 V
circuit branch end and ground (Note: if hot short
occurs across them, the charging lamp will be
lighted as the starting switch is ON.
Between EC2 (33) – ground Voltage Max. 1 V
Between EC2 (39) – ground Voltage 20 – 30 V
Between EC2 (3), (4) – ground Voltage 20 – 30 V
Between EC3 (1), (2) – ground Voltage Max. 1 V
WA200-6 7
8 WA200-6
WA200-6 9
E-2 Preheater does not operate normally 1

a) Preheater does not operate
Contents of
• When temperature is low (engine boost air temperature is below –4°C), preheater does not operate.
trouble
• If failure codes are displayed, carry out troubleshooting for them first.
Related • Engine boost air temperature can be checked with monitoring function.
information (Monitoring code: ENG-18500-CHG TEMP (°C))
(Monitoring code: ENG-18501-CHG TEMP (V))

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay E06 – R90 Resistance
Defective heater relay When 24 V is applied
1 Max. 1 z
(Internal defect) (When relay is “ON”)
Between E05 – E07A
Other than above
Min. 1 Mz
(When relay is “OFF”)
Between E06 – R90 19 – 25 z
Defective intake air heater without turning starting switch ON.
2
(Internal defect) Resis- 0.17 –
Between E07B – ground
tance 0.27 z
a Replace diode (E06A).
Condition becomes normal. Diode (E06A) is defective.
Possible
causes and Condition does not become nor-
Diode (E06A) is normal.
standard value Defective diode (E06A) mal.
3
in normal state (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting
a Measure in diode range.
Between (2) – (1)
Continuity is secured.
a Apply (+) side of tester to (2).
ness (Disconnection in wiring Resis-
4 Wiring harness between E07A – E07B Max. 1 z
or defective contact in connec- tance
tor) Resis-
Wiring harness between R11 – E05 Max. 1 z
tance
Ground fault in wiring harness Between wiring harness E07A – E07B and Resis-
5 Min. 1 Mz
(Contact with GND circuit) ground tance
Between wiring harness R11 – E05 and Resis-
Min. 1 Mz
ground tance
10 WA200-6
WA200-6 11
b) Preheater operates constantly

Contents of
• Preheater operates constantly.
trouble
• If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it first.
Related • Engine boost air temperature can be checked with monitoring function.
information (Monitoring code: ENG-18500-CHG TEMP (°C))
(Monitoring code: ENG-18501-CHG TEMP (V))

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay E06 – R90 Resistance
Defective heater relay When 24 V is applied
1 Max. 1 z
(Internal defect) (When relay is "ON")
Between E05 – E07A
Other than above
Min. 1 Mz
Between E06 – R90 19 – 25 z
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Ground fault in wiring harness without turning starting switch ON.
2
standard value (Contact with GND circuit) Between wiring harness EC2 (40) – E06 (5) Resis-
Min. 1 Mz
in normal state and ground tance
When
Hot short (Contact with 24V preheater Voltage 20 – 30 V
3
circuit) in wiring harness Between wiring harness E07A – is ON
E07B and ground When
preheater Voltage Max. 1 V
is OFF
If cause 1 – 3 are not detected, engine controller may be defective.

a See the circuit diagram in “E-2 a) Preheater does not operate”.
12 WA200-6
WA200-6 13
E-3 Defective boom kick-out function and cancellation 1

Contents of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity
trouble switch system, boom kick-out PPC detent system and lift arm detent relay system.
Related
—
information

a Replace boom kick-out relay (L113) with normal relay.
a Operate boom kick-out with engine started.
Boom kick-out function is normal. Defective relay L113.
Boom kick-out does not function. Relay L113 is normal.
a Turn starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boom kick-out relay
1 Resis- 200 – 400
(L113) (Internal trouble) Between L113 (male) (1) and (2)
tance z
a Solid part check.
Between Applies 24V impressed voltage Resis-
Max. 1 z
L113 between L113 (male) (1) – (2) tance
(male) (3) Does not apply voltage between Resis-
and (5) Min. 1 Mz
L113 (male) (1) – (2) tance
a Replace detent active relay (L115) with normal relay.
Boom kick-out function is normal. Defective relay L115.
Boom kick-out does not function. Relay L115 is normal.
Possible without turning starting switch ON.
causes and
standard value Defective detent active relay Resis- 200 – 400
2 Between L115 (male) (1) and (2)
in normal state (Internal trouble) tance z
a Solid part check.
a Applies impressed voltage between L115 (male) (1) – (2)
Max. 1 z
and (5) Min. 1 Mz
L115 (male) (1) – (2) tance
Prepare with starting switch OFF, then carry out troubleshooting
Defective boom kick-out PPC Resis-
3 Between L36 (male) (1) and (2) 30 – 50 z
detent (Internal trouble) tance
Resis-
Between L36 (male) (1), (2) – ground Min. 1 Mz
tance
a Interchange lift arm positioner proximity switch (F04) with bucket
positioner proximity switch (F03).
Defective lift arm positioner
Defective boom kick-
4 proximity switch (Internal trou-
Boom kick-out function is normal. out proximity switch
ble)
F04
Boom kick-out prox-
Boom kick-out does not function. imity switch F04 is
normal.
14 WA200-6

Wiring harness between F04 (female) (A) Resis-
Max. 1 z
and fuse (FS1) (13) tance
Wiring harness between F04 (female) (B) Resis-
Max. 1 z
and L113 (female) (2) tance
Wiring harness between F04 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3) and L115 (female) (5) tance
5 (Disconnection or defective Wiring harness between L115 (female) (3) Resis-
Max. 1 z
contact) and fuse FS1 (13) tance
Wiring harness between L113 (female) (5) Resis-
Max. 1 z
Max. 1 z
and ground tance
Wiring harness between E02 (female) (1) – Resis-
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the boom kick-out does not function
Possible
causes and Wiring harness between F04 (female) (B) Resis-
standard value Min. 1 Mz
and L113 (female) (2) and ground tance
in normal state
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
Wiring harness ground fault Wiring harness between F04 (female) (A) Resis-
6 Min. 1 Mz
(Contact with GND circuit) and fuse (FS1) (13) and ground tance
Min. 1 Mz
(3) and L115 (female) (5) and ground tance
Min. 1 Mz
and fuse FS1 (13) and ground tance
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever
returns to neutral)

Voltage Max. 1 V
Hot short-circuiting between L36 (female) (1) and ground
7 harnesses (Contact with 24V a In this case, the boom kick-out does not function (lever does not
circuit) return to neutral)
Wiring harness between L113 (female) (1),
Voltage Max. 1 V
(3) – L115 (female) (5) and ground
a In this case, lift arm detent operates even if engine is stopped.
WA200-6 15

a Prepare with starting switch OFF, then turn starting switch ON,
Possible raise lift arm to the highest position (kick-out operated), and carry
causes and Hot short-circuiting between out troubleshooting.
standard value 7 harnesses Wiring harness between F04 (female) (B) –
in normal state Voltage Max. 1 V
(Contact with 24V circuit) L113 (female) (2) and ground
a In this case, boom kick-out detent does not function (lever returns
to neutral).
16 WA200-6
WA200-6 17
E-4 Defective bucket positioner function and cancellation 1

Contents of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proxim-
trouble ity switch system, bucket PPC detent system and bucket detent relay system.
Related
—
information

a Replace bucket leveler relay (L114) with normal relay.
a Operate bucket positioner with engine started.
Bucket positioner function is normal. Defective relay L114.
Bucket positioner does not function. Relay L114 is normal.
Defective bucket leveler relay Resis- 200 – 400
(L114) tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L114 (male) (1) – (2) tance
Possible a Turn starting switch OFF.
causes and a Replace detent active relay (L115) with normal relay.
standard value a Operate boom kick-out with engine started.
in normal state Boom kick-out function is normal. Defective relay L115.
Relay L115 is
Boom kick-out does not function.
normal.
Defective detent active relay
2 Resis- 200 – 400
(L113) Between L115 (male) (1) and (2)
tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L115 (male) (1) – (2) tance
3 Defective bucket PPC detent
Resis-
Between L37 (male) (1) and (2) 30 – 50 z
tance
18 WA200-6

a Interchange bucket positioner proximity switch (F03) with lift arm
a Operate bucket positioner with engine started.
Defective bucket positioner Defective bucket
4
proximity switch Bucket positioner function is normal. positioner proximity
switch F03
Bucket positioner
Bucket positioner does not function. proximity switch F03
is normal.
Max. 1 z
and fuse FS1 (13) tance
Possible
Max. 1 z
standard value and L114 (female) (2) tance
in normal state Wiring harness between F03 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3), and L115 (female) (5) tance
Max. 1 z
Max. 1 z
Max. 1 z
and ground tance
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the bucket positioner does not function
WA200-6 19

Wiring harness between F03 (female) (B) – Resis-
Min. 1 Mz
a In this case, the bucket positioner detent does not function (lever
does not return to neutral)
Min. 1 Mz
a In this case, the bucket positioner does not function (lever returns
to neutral)
6 Wiring harness ground fault
Wiring harness between F03 (female) (A) – Resis-
Min. 1 Mz
fuse FS1 (13) and ground tance
Min. 1 Mz
(3) – L115 (female) (5) and ground tance
Min. 1 Mz
fuse FS1 (13) and ground tance
Possible Wiring harness between E02 (female) (1) – Resis-
Min. 1 Mz
causes and L115 (female) (1) and ground tance
standard value a In this case, the fuse is blown and no detents function (lever
in normal state returns to neutral)

Voltage Max. 1 V
a In this case, the bucket positioner does not function (lever does
not return to neutral)
Voltage Max. 1 V
Hot short-circuiting between
7 Wiring harness between E02 (female) (1) –
harnesses Voltage Max. 1 V
a In this case, bucket detent operates even if engine is stopped.
a Prepare with starting switch OFF, then turn starting switch ON, tilt
bucket, and carry out troubleshooting.
Wiring harness between F03 (female) (B) –
Voltage Max. 1 V
a In this case, bucket positioner detent does not function (lever
returns to neutral).
20 WA200-6
WA200-6 21
E-5 Defective lift arm FLOATING holding function and cancellation 1

Contents of • Lift arm FLOATING holding does not function or cannot be cancelled due to defective boom kick-out
trouble proximity switch system, lift arm FLOATING PPC detent system and lift arm detent relay system.
Related
—
information

a Replace boom kick-out relay (L113) with normal relay.
a Operate lift arm FLOATING with engine started.
Lift arm FLOATING function is normal. Defective relay L113.
Lift arm FLOATING does not function. Relay L113 is normal.
a Turn starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boom kick-out relay
1 Resis- 200 – 400
(L113) (Internal trouble) Between L113 (male) (1) and (2)
tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L113 (male) (1) – (2) tance
a Replace detent active relay (L115) with normal relay.
Lift arm FLOATING function is normal. Defective relay L115.
Lift arm FLOATING does not function. Relay L115 is normal.
causes and
standard value Defective detent active relay Resis- 200 – 400
in normal state (Internal trouble) tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
L115 (male) (1) – (2) tance
Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm floating PPC Resis-
3 Between L35 (male) (1) and (2) 30 – 50 z
detent (Internal trouble) tance
Resis-
Between L35 (male) (1), (2) – ground Min. 1 Mz
tance
a Interchange lift arm positioner proximity switch (F04) with bucket
Defective lift arm positioner
Defective boom kick-
4 proximity switch (Internal trou-
Lift arm FLOATING function is normal. out proximity switch
ble)
F04
Boom kick-out prox-
Lift arm FLOATING does not function. imity switch F04 is
normal.
22 WA200-6

Max. 1 z
and fuse (FS1) (13) tance
Wiring harness between F04 (female) (B) Resis-
Max. 1 z
Wiring harness between F04 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3) and L115 (female) (5) tance
Max. 1 z
Max. 1 z
Max. 1 z
and ground tance
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the boom kick-out does not function
Possible
standard value Min. 1 Mz
in normal state
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
Wiring harness ground fault Wiring harness between F04 (female) (A) Resis-
6 Min. 1 Mz
(Contact with GND circuit) and fuse (FS1) (13) and ground tance
Min. 1 Mz
(3) and L115 (female) (5) and ground tance
Min. 1 Mz
and fuse FS1 (13) and ground tance
Wiring between harness E02 (female) (1) – Resis-
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever
returns to neutral)

Wiring harness between L113 (female) (5)
Voltage Max. 1 V
Hot short-circuiting between and L35 (female) (1) and ground
7 harnesses (Contact with 24V a In this case, the boom kick-out does not function (lever does not
circuit) return to neutral)
Wiring between harness L113 (female) (1),
Voltage Max. 1 V
a In this case, lift arm detent operates even if engine is stopped.
WA200-6 23

a Prepare with starting switch OFF, then turn starting switch ON,
Possible operate lift arm FLOATING, and carry out troubleshooting.
causes and Hot short-circuiting between
standard value Wiring harness between F04 (female) (B) –
7 harnesses Voltage Max. 1 V
in normal state L113 (female) (2) and ground
(Contact with 24V circuit)
a In this case, lift arm FLOATING detent does not function (lever
returns to neutral).
24 WA200-6
WA200-6 25
E-6 Travel direction selection system does not function 1

a) When parking brake is released, parking brake indicator of machine monitor keeps lighting.
Contents of • Machine does not travel forward and reverse because of trouble in parking brake system, forward
trouble solenoid valve system or directional lever system.
• Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
• If any failure code is displayed, carry out troubleshooting for it first.
Related
• Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
information
function of machine monitor.
(Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2)
• Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19)

Defective parking brake bot- Parking brake
1 tom switch (Malfunction or L47 (male) Resistance
lever position
wrong positioning)
Bottom Max. 1 z
Between (1) – (2)
Possible Disconnection in wiring har- without turning starting switch ON.
causes and ness (Disconnection in wiring Wiring harness between HST (female) (16), Resis-
standard value 2 Max. 1 z
or defective contact in connec- L27 (female) (1), (6) – (2) – L47 (female) (2) tance
in normal state tor) Resis-
L47 (female) (1) – ground Max. 1 z
tance
Defective diodes (D02)
3 Measure at (5) in
(Internal trouble) Between (5) and (1) Continue
diode range
Measure at (7) in
diode range
26 WA200-6
WA200-6 27
b) When parking brake is released, parking brake indicator of machine monitor goes off but machine
does not travel forward
Contents of • Machine does not travel forward because of trouble in parking brake system, forward solenoid valve
trouble system or directional lever system.
• Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
• If any failure code is displayed, carry out troubleshooting for it first.
Related
• Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
information
function of machine monitor.
(Monitoring code: HST – 40977 – D-IN-0, D-IN-1, D-IN-2)
• Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST – 40980 – D-OUT-18, D-OUT-19)

Resis-
1 Defective forward solenoid Between T01 (male) (1) – (2) 30 – 60 z
(Internal defect) tance
Resis-
Between T01 (male) (1), (2) – ground Min. 1 Mz
tance
Resis-
2 Defective reverse solenoid Between T01 (male) (3) – (4) 30 – 60 z
(Internal defect) tance
Resis-
Between T01 (male) (3), (4) – ground Min. 1 Mz
tance
FNR (Directional)
lever
F (Forward) Max. 1 z
Possible Defective FNR (directional) Between (1) – (2)
3 lever switch (Internal defect) Other than above Min. 1 Mz
causes and
standard value N (Neutral) Max. 1 z
Between (1) – (3)
in normal state Other than above Min. 1 Mz
R (Reverse) Max. 1 z
Between (1) – (4)
ing brake, and carry out troubleshooting.
FNR (Directional)
HST Voltage
lever
N (Neutral) 20 – 30 V
Other than above Max. 1 V
28 WA200-6
WA200-6 29
E-7 Wiper does not operate 1

Contents of
(1) Front wiper does not operate.
trouble
Related
• The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
information

1
L57 Front wiper switch Voltage
Between (6) and
ground
Defective front wiper motor
2 Between (2) and
(Internal defect) Lo 20 – 30 V
ground
Between (1) and
Hi 20 – 30 V
ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between L57 (5) and ground until wiper motor stops.
L48 Front wiper switch Voltage
Between (3) and
Possible Constant 20 – 30 V
ground
causes and
standard value Defective wiper timer (relay) Between (4) and
3 INT 20 – 30 V
in normal state (Internal defect) ground
Between (2) and
Washer side 20 – 30 V
ground
INT (If wiper switch is
Between (5) and Repeat 20 to 30 V o
set in INT, voltage is
ground 0V
output intermittently.)
L05 Voltage
Between (7) and ground 20 – 30 V
Defective front wiper switch
4 L05 Front wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (3) and (5) INT Max. 1 z
30 WA200-6

Max. 1 z
Disconnection in wiring har- Max. 1 z
ness
5 Wiring harness between L05 (female) (7) –
(Disconnection or defective Resis-
contact in connector) fuse No. 14 of fuse box (FS1), – circuit Max. 1 z
tance
branch end
Max. 1 z
Possible Wiring harness between L57 (female) (3) – Resis-
causes and Max. 1 z
ground tance
standard value
in normal state
Resis-
L48 (female) (5), – circuit branch end and Min. 1 Mz
tance
ground
Grounding fault in wiring har- Resis-
6 ness tance
ground
Resis-
fuse No. 14 of fuse box (FS1), – circuit Min. 1 Mz
tance
branch end and ground
Resis-
tance
ground
WA200-6 31
Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information

L52 Rear wiper switch Voltage
Between (1) and
Defective rear wiper motor Constant 20 – 30 V
1 ground
(Internal trouble)
Between (2) and
ON 20 – 30 V
ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between L52 (3) and ground until wiper motor stops.
L05 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal trouble)
L05 Rear wiper switch Resistance
Between (7) and (9) ON Max. 1 z
Possible
causes and Between (8) and (9) OFF Max. 1 z
standard value Other than above Min. 1 Mz
in normal state
Max. 1 z
Disconnection in wiring har- fuse No. 14 of fuse box (FN1) tance
ness Wiring harness between L05 (female) (8) – Resis-
3 Max. 1 z
(Disconnection or defective L52 (female) (3) tance
contact in connector) Wiring harness between L05 (female) (9) – Resis-
Max. 1 z
Max. 1 z
ground tance
Resis-
Ground fault in wiring harness branch end and ground tance
4
Min. 1 Mz
Min. 1 Mz
32 WA200-6
WA200-6 33
E-8 Windshield washer does not operate 1

Contents of
Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-7 Wiper does not operate” first.)

a Prepare with starting switch OFF, then hold starting switch OFF or
turn it ON and carry out troubleshooting.
B07 Front wiper switch Voltage/Resistance
Defective front washer motor
1 Between (1) – ground Window washer 20 – 30 V
(Internal defect)
Between (2) – ground operation position Max. 1 z
If voltage and resistance are normal but front washer does not oper-
ate, front washer motor is defective.
B06 Rear wiper switch Voltage/Resistance
Between (1) – ground Window washer 20 – 30 V
Defective rear washer motor Between (2) – ground operation position Max. 1 z
2
(Internal defect) If voltage and resistance are normal but rear washer does not oper-
ate, rear washer motor is defective.
B07 Front wiper switch Voltage/Resistance
L05 Voltage
Possible Between (7) and ground 20 – 30 V
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
Defective front wiper switch
in normal state 3
(Internal defect) Washer switch for
front wiper
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Between (7), (6) and
Constant Min. 1 Mz
ground
L05 Voltage
Defective rear wiper switch without turning starting switch ON.
4
(Internal defect) Washer switch for
rear wiper
ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
ground
34 WA200-6

Washer switch for
L48 Voltage
front wiper
Defective wiper timer (relay) Between (3) and
5 Constant 20 – 30 V
(for only front wiper) ground
Between (2) and
ON 20 – 30 V
ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
ground
Max. 1 z
Possible Disconnection in wiring har- B07 (female) (1), – L48 (female) (2) tance
causes and ness Wiring harness between L05(female) (7) – Resis-
standard value 6 Max. 1 z
(Disconnection or defective fuse No. 14 of fuse box (FS1) tance
in normal state contact in connector) Wiring harness between L05 (female) (10) – Resis-
Max. 1 z
B06 (female) (1) tance
Wiring harness between B07 (female) (2), Resis-
Max. 1 z
B06 (female) (2) – ground tance
Resis-
B07 (female) (1), – L48 (female) (2), – circuit Min. 1 Mz
tance
Ground fault in wiring harness
7
(Contact with ground circuit) Wiring harness between L05 (female) (7) – Resis-
tance
Resis-
B06 (female) (1), – circuit branch end and Min. 1 Mz
tance
ground
WA200-6 35
36 WA200-6
WA200-6 37
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off 1
Contents of
(1) Headlamp, clearance lamp and tail lamp do not light up or go off.
trouble
• Since the lamp system GND circuit is disconnected or shorted with the ground, none of the lamps
lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, machine monitor night lamp light up
(when normal).
• Headlamp at HEAD position: Above lamps and headlamp light up (when normal).
Related
• The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
information
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).

L04 (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (2) and (3) 1st line Min. 1 Mz
Possible 1
(Internal trouble)
causes and 2nd line Max. 1 z
standard value OFF Min. 1 Mz
in normal state
Between (1) and (3) 1st line Max. 1 z
2nd line Max. 1 z
2
(Disconnection or defective Wiring harness between L04 (female) (3) – Resis-
connector contact) Max. 1 z
ground tance
38 WA200-6
Contents of
(2) Either of headlamp (low and high beams) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• Carry out the following troubleshooting when the clearance lamp and tail lamp light up and go off nor-
mally.
Related
information

Defective fuses No. 8 and No. If the fuse is burn, the circuit probably has a grounding fault, etc.
1
9 of fuse box (FS1) (See cause 7.)
Between (1) and (2) 200 – 400 z
Defective headlamp relay, left
(L120) (Internal trouble)
When headlamp relay (L120) is replaced with a relay of the same
type, if the condition becomes normal, the headlamp relay is defec-
tive.
Between (1) and (2) 200 – 400 z
Possible Defective headlamp relay,
causes and right (L119)
standard value and carry out troubleshooting.
in normal state When headlamp relay (L119) is replaced with a relay of the same
type, if the condition becomes normal, the headlamp relay is defec-
tive.
Defective lamp switch L04 (male) Headlamp switch Resistance

4
(Internal trouble) OFF Min. 1 Mz
Between (2) and (3) 1st position Min. 1 Mz
2nd position Max. 1 z
L04 (male) Dimmer switch Resistance
Defective dimmer switch Low Min. 1 Mz
5
High Max. 1 z
Low Max. 1 z
Between (4) and (3)
High Min. 1 Mz
WA200-6 39

Max. 1 z
Max. 1 z
box (FS1) – L120 (female) (1), (3) tance
Max. 1 z
ness L25 (female) (1), – left FLH (female) (B) tance
6
(Disconnection or defective a Carry out above 3 items when left side does not light.
Max. 1 z
Max. 1 z
Max. 1 z
right FLH (female) (B) tance
a Carry out above 3 items when right side does not light.
Resis-
tance
ground
a Carry out above when left side does not go off.
Possible
causes and Wiring harness between fuse No. 8 of fuse
Resis-
standard value box (FS1) – L120 (female) (1), (3) and Min. 1 Mz
tance
in normal state ground
Resis-
Ground fault in wiring harness L25 (female) (1), – left FLH (female) (B) and tance
Min. 1 Mz
7 ground
a Carry out above 2 items when left side does not light.
Min. 1 Mz
a Carry out above when right side does not go off.
Wiring harness between fuse No. 9 of fuse
Resis-
box (FS1) – L119 (female) (1), (3) and Min. 1 Mz
tance
ground
Min. 1 Mz
right FLH (female) (B) and ground tance
a Carry out above 2 items when right side does not light.
• Headlamp switch is OFF
Hot short in wiring harness L25 (female) (1), – left FLH (female) (B) and Voltage Max. 1 V
8 ground
a Carry out above when left side does not go off.
Voltage Max. 1 V
right FLH (female) (B) and ground
a Carry out above when left side does not light.
40 WA200-6
Contents of
(3) Headlamp (low beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
2
High Max. 1 z
Possible Low Max. 1 z
Between (4) and (3)
causes and High Min. 1 Mz
standard value
in normal state
ness
3 Wiring harness between FLH (female) (A) – Resis-
(Disconnection or defective Max. 1 z
contact in connector)
Reference: Connector "FLH" is installed to both right and left sides.
Ground fault in wiring harness
4 Wiring harness between FLH (female) (A) – Resis-
(Contact with ground circuit) Min. 1 Mz
WA200-6 41
Contents of
(4) Headlamp (high beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
2
High Max. 1 z
Low Max. 1 z
Possible Between (4) and (3)
causes and High Min. 1 Mz
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state Disconnection in wiring har- without turning starting switch ON.
ness
3 Wiring harness between FLH (female) (C) – Resis-
(Disconnection or defective Max. 1 z
Ground fault in wiring harness Wiring harness between FLH (female) (C) –
4 Resis-
(Contact with ground circuit) L04 (female) (5), – circuit branch end and Min. 1 Mz
tance
ground
42 WA200-6
Contents of (5) Clearance lamp does not light up or go off.

trouble (6) Tail lamp does not light up or go off.
• Defective switch, lamp, or wiring harness of the clearance lamp or tail lamp system.
Related • When the headlamp and turn signal lamp light up.
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuses No. 10 and If the fuse is burn, the circuit probably has a grounding fault, etc.
2
No. 11 of fuse box (FS2) (See cause 5.)
Between (1) and (2) 200 – 400 z
Defective small lamp relay, left
When small lamp relay (L117) is replaced with a relay of the same
type, if the condition becomes normal, the small lamp relay is defec-
tive.
Between (1) and (2) 200 – 400 z
Defective small lamp relay,
right (L118) (Internal trouble)
Possible When small lamp relay (L118) is replaced with a relay of the same
causes and type, if the condition becomes normal, the small lamp relay is defec-
standard value tive.
in normal state
Defective lamp switch L04 (male) Lamp switch Resistance

5
(Internal trouble) OFF Min. 1 Mz
Between (1) and (3) 1st position Max. 1 z
2nd position Max. 1 z
Max. 1 z
L117 (female) (2), – L118 (female) (2) tance
Max. 1 z
Disconnection in wiring har-
ness a Carry out above 2 items when left side does not light.
6
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
a Carry out above when right side does not light.
Max. 1 z
FLC1 (female) (A), – R22 (female) (6) tance
Max. 1 z
FLC (female) (A), – R23 (female) (6) tance
WA200-6 43

Resis-
L117 (female) (2), – L118 (female) (2) and Min. 1 Mz
tance
ground
a Carry out above when lamp does not go off.
Resis-
tance
ground
Ground fault in wiring harness a Carry out above when left side does not go off.
7
(Contact with ground circuit) Wiring harness between fuse No. 11 of fuse
Resis-
tance
ground
Possible a Carry out above when right side does not light.
causes and Wiring harness between L117 (female) (5) –
Resis-
standard value FLC1 (female) (A), – R22 (female) (6) and Min. 1 Mz
tance
Resis-
FLC (female) (A), – R23 (female) (6) and Min. 1 Mz
tance
ground
• Headlamp switch is OFF
L117 (female) (2), – L118 (female) (2), – cir- Voltage Max. 1 V
Hot short in wiring harness cuit branch end and ground
8
(Contact with 24V circuit) Wiring harness between L117 (female) (5) –
FLC1 (female) (A), – R22 (female) (6), – cir- Voltage Max. 1 V
cuit branch end and ground
FLC (female) (A), – R23 (female) (6), – cir- Voltage Max. 1 V
44 WA200-6
WA200-6 45
E-10 Working lamp does not light up or go off 1

Contents of
(1) Front working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the front working lamp system is defective
Related • When the rear working lamp is normal
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
2
Between (1) and (2) 200 – 400 z
Defective front working lamp
3
relay (L122) (Internal trouble) a Prepare with starting switch OFF, then turn starting switch ON
When front working lamp relay (L122) is replaced with a relay of the
same type, if the condition becomes normal, the front working lamp
relay is defective.
causes and Front working lamp
standard value Defective front working lamp switch
in normal state 4
switch (Internal trouble) ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
ground
Max. 1 z
Max. 1 z
ness ground tance
5
box (FS2) – L07 (female) (6), L122 (female) (3) tance
Max. 1 z
C04 (female) (1), – C05 (female) (1) tance
Wiring harness between C04 (female) (2), Resis-
Max. 1 z
C05 (female) (2) – ground tance
46 WA200-6

Min. 1 Mz
Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse
6 Resis-
(Contact with ground circuit) box (FS2) – L07 (female) (6), L122 (female) Min. 1 Mz
tance
(3) and ground
Possible
Resis-
standard value C04 (female) (1), – C05 (female) (1), – circuit Min. 1 Mz
tance
in normal state branch end and ground
• Front working lamp switch turned off
Hot short in wiring harness Wiring harness between L07 (female) (5) –
7 Voltage Max. 1 V
C04 (female) (1), – C05 (female) (1), – circuit Voltage Max. 1 V
WA200-6 47
Contents of
(2) Rear working lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related • When the front working lamp is normal
information • If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) and (2) 200 – 400 z
Defective rear working lamp
3
When rear working lamp relay (L123) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
causes and Rear working lamp
Defective rear working lamp L08 (male) Resistance
standard value switch
in normal state 4 switch
ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
ground
Max. 1 z
Max. 1 z
ness ground tance
5
box (FS2) – L08 (female) (6), L123 (female) (3) tance
Max. 1 z
B01 (female) (1), – B02 (female) (1) tance
Wiring harness between B01 (female) (2), Resis-
Max. 1 z
B02 (female) (2) – ground tance
48 WA200-6

Max. 1 z
Ground fault in wiring harness Wiring harness between fuse No. 13 of fuse
6 Resis-
(Contact with ground circuit) box (FS2) – L08 (female) (6), L123 (female) Max. 1 z
tance
(3) and ground
Possible
Resis-
standard value B01 (female) (1), – B02 (female) (1), – circuit Max. 1 z
tance
in normal state branch end and ground
• Front working lamp switch turned off
Hot short in wiring harness Wiring harness between L08 (female) (5) –
7 Voltage Max. 1 V
B01 (female) (1), – B02 (female) (1), – circuit Voltage Max. 1 V
WA200-6 49
50 WA200-6
E-11 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch
(right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
Related
D-IN-12).
information
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left
turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-
IN-13).

Defective No.2 and No.10 If the fuse is burn, the circuit probably has a grounding fault, etc.
1
fuses of fuse box (FS1) (See cause 8.)
Defective hazard relay (L125) Between (1) and (2) 200 – 400 z
2
(Internal trouble) a Prepare with starting switch OFF, then turn starting switch ON
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Possible Between (5) and (6) 200 – 400 z
causes and
Defective hazard/turn signal (1), (2), (3), (4) – (6) Min. 1 Mz
standard value 3
relay (L124)
in normal state a Prepare with starting switch OFF, then turn starting switch ON
When hazard/turn signal relay (L124) is replaced with a relay of the
same type, if the condition becomes normal, the hazard/turn signal
relay is defective.
L49 Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit 20 – 30 V and 0 V are indicated
4 Between (4) and (1)
(Internal trouble) repeatedly.
Between (3), (4) and ground Min. 1 Mz
WA200-6 51

Max. 1 z
5
L04 (female) (6), L124 (female) (1), (3) tance
Max. 1 z
ground tance
Min. 1 Mz
Resis-
L04 (female) (6), L124 (female) (1), (3) and Min. 1 Mz
Ground fault in wiring harness tance
6 ground
Possible (Contact with ground circuit)
Resis-
standard value R23 (female) (1) – FLC [left] (female) (C) and Min. 1 Mz
tance
Resis-
R22 (female) (1) – FLC [right] (female) C and Min. 1 Mz
tance
ground
Voltage Max. 1 V
L04 (female) (6), L124 (female) (1), (3) and Voltage Max. 1 V
7 ground
R23 (female) (1) – FLC [left] (female) (C) and Voltage Max. 1 V
ground
R22 (female) (1) – FLC [right] (female) C and Voltage Max. 1 V
ground
52 WA200-6
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• When the hazard lamp lights up.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
Related (right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
information D-IN-12).
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
(left turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
D-IN-13).

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
Turn signal lamp
switch
Defective turn signal lamp Left Min. 1 Mz

2 Between (6) and (7)
switch (Internal trouble) Right Max. 1 z
Left Max. 1 z
Between (6) and (8)
Right Min. 1 Mz
a Prepare with starting switch OFF, then check relay unit.
3 Defective hazard relay (L125) Resis-
Between L125 (female) (3) – (6) Max. 1 z
tance
Wiring harness between fuse box FS1 No. Resis-
Possible Max. 1 z
10 – L125 (female) (6) tance
causes and
in normal state
Max. 1 z
Disconnection in wiring har- R23 (female) (1), – FLC (female) (C) tance
ness Wiring harness between L04 (female) (8) – Resis-
4 Max. 1 z
(Disconnection or defective R22 (female) (1), – FLC1 (female) (C) tance
contact in connector) Wiring harness between R22 (female) (4) – Resis-
Max. 1 z
ground tance
Wiring harness between R23 (female) (4) – Resis-
Max. 1 z
ground tance
Wiring harness between FLC (female) (B) – Resis-
Max. 1 z
ground tance
Wiring harness between FLC1 (female) (B) – Resis-
Max. 1 z
ground tance
Ground fault in wiring harness without turning starting switch ON.
5
(Contact with ground circuit) Wiring harness between fuse box FS1 No. Resis-
Min. 1 Mz
10 – L125 (female) (6) and ground tance
WA200-6 53
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.

1
Defective hazard relay (L125) Between (1) and (2) 200 – 400 z
2
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Between (1) and (2) 200 – 400 z
Defective hazard/turn signal
3
When hazard/turn signal relay (L124) is replaced with a relay of the
same type, if the condition becomes normal, the hazard/turn signal
relay is defective.
Possible
causes and
standard value
Defective hazard lamp switch L06 (male) Hazard lamp switch Resistance
in normal state 4
(Internal trouble)
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Max. 1 z
box (FS1) – L125 (female) (5) tance
Max. 1 z
Max. 1 z
Disconnection in wiring har- L06 (female) (5) tance
ness Resis-
5 Between L124 (female) (6) – ground Max. 1 z
(Disconnection or defective tance
contact in connector) Resis-
Between L125 (female) (2) – ground Max. 1 z
tance
Between L49 (female) (4) – L124 (female) Resis-
Max. 1 z
(1), (3) tance
Between L124 (female) (2) – FLC [right] (C), Resis-
Max. 1 z
R23 (1) tance
Between L124 (female) (4) – FLC [left] (C), Resis-
Max. 1 z
R22 (1) tance
54 WA200-6

Min. 1 Mz
Ground fault in wiring harness box (FS1) – L125 (female) (5) and ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 2 of fuse Resis-
Min. 1 Mz
Min. 1 Mz
L06 (female) (1), (5) and ground tance
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting.
standard value • When hot short resulted on the wiring harnesses of the following
in normal state two circuits
R23 (female) (1), – FLC (female) (C), – cir- Voltage Max. 1 V
Hot short in wiring harness cuit branch end and ground
7
R22 (female) (1), – FLCL (female) (C), – cir- Voltage Max. 1 V
L125 (female) (1) – L06 (female) (1), (5) and Voltage Max. 1 V
ground
WA200-6 55
56 WA200-6
WA200-6 57
E-12 Brake lamp does not light or it keeps lighting up 1

Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
Defective fuse No.11 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
2
Between (1) and (2) 200 – 400 z
Defective brake lamp relay
When brake lamp relay (L121) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
L34 (male) Brake pedal Resistance
Defective brake lamp switch
4 Press Max. 1 z
Released Min. 1 Mz
Possible Constant Min. 1 Mz
ground
causes and
in normal state without turning starting switch ON.
Resis-
box (FS1) – L121 (female) (3), – L34 Max. 1 z
tance
(female) (1)
ness Max. 1 z
5 L121 (female) (1) tance
(Disconnection or defective
Max. 1 z
ground tance
Max. 1 z
R22 (female) (5), R23 (female) (5) tance
Wiring harness between R22 (female) (4), Resis-
Max. 1 z
R23 (female) (4) – ground tance
Resis-
box (FS1) – L121 (female) (3), – L34 Min. 1 Mz
tance
Ground fault in wiring harness (female) (1), – circuit branch end and ground
6
(Contact with ground circuit) Wiring harness between L34 (female) (2) – Resis-
Min. 1 Mz
Resis-
R22 (female) (5), – R23 (female) (5) and Min. 1 Mz
tance
ground
58 WA200-6

Possible and carry out troubleshooting.
standard value Hot short in wiring harness Voltage Max. 1 V
7 L121 (female) (1) and ground
in normal state (Contact with 24V circuit)
R22 (female) (5), – R23 (female) (5) and Voltage Max. 1 V
ground
WA200-6 59
E-13 Backup lamp does not light or it keeps lighting up 1

Contents of
Backup lamp does not light or it keeps lighting up.
trouble
• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated.
information Carry out troubleshooting for it first.)
• If another failure code is displayed, carry out troubleshooting for it first.

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) and (2) 200 – 400 z
Defective backup lamp 1 relay
When backup lamp 1 relay (L109) is replaced with a relay of the
same type, if the condition becomes normal, the backup lamp 1
relay is defective.
causes and without turning starting switch ON.
standard value L126 (male) Resistance
in normal state
Defective backup lamp 2 relay Between (1) and (2) 200 – 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
relay is defective.
Between (1) and (2) 200 – 400 z
Defective FR pressure select
5
When FR pressure select relay (L101) is replaced with a relay of the
same type, if the condition becomes normal, the FR pressure select
relay is defective.
60 WA200-6

Max. 1 z
Max. 1 z
R22 (female) (2), – R23 (female) (2) tance
Max. 1 z
Reference: Following 4 items are circuits for turning lamp ON with
directional lever in R position.
Max. 1 z
Max. 1 z
R22 (female) (2), – R23 (female) (2) tance
Max. 1 z
Disconnection in wiring har- Max. 1 z
ground tance
ness
6 Reference: Following 4 items are circuits for turning lamp ON when
(Disconnection or defective
contact in connector) HST controller outputs signal to reverse solenoid.
Max. 1 z
Max. 1 z
R22 (female) (2) or R23 (female) (2) tance
Possible
causes and Wiring harness between HST (female) (20) – Resis-
Max. 1 z
standard value L101 (female) (5) tance
in normal state Wiring harness between L101 (female) (6) – Resis-
Max. 1 z
ground tance
Max. 1 z
ground tance
Max. 1 z
ground tance
Wiring harness between fuse box FS1 No. 5 Resis-
Max. 1 z
– L24 (female) (4), (5) tance
Reference: If above wiring harness is disconnected, when directional
switch is set in R and lamp lights and then directional lever or direc-
tional switch is set in position other than R, lamp may not go off.
Resis-
box (FS2) – L109 (female) (3), (1) – circuit Min. 1 Mz
tance
Ground fault in wiring harness branch end and ground
7
(Contact with ground circuit) Wiring harness between L109 (female) (5) –
Resis-
R22 (female) (2), – R23 (female) (2), – circuit Min. 1 Mz
tance
Min. 1 Mz
R22 (female) (2), – R23 (female) (2), – circuit Voltage Max. 1 V
WA200-6 61
62 WA200-6
E-14 Backup alarm does not sound or it keeps sounding 1

Contents of
Backup alarm does not sound or it keeps sounding.
trouble
• The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. In
information such case, give precedence to the troubleshooting of the failure indicated with the code.)
• If another failure code is displayed, carry out troubleshooting for it first.

Defective backup alarm B03 Gear shift lever Voltage
1
(Internal trouble)
R 20 – 30 V
Between (1) and (2)
Other than R Max. 1 V
2
Between (1) and (2) 200 – 400 z
Defective backup lamp 1 relay
Possible same type, if the condition becomes normal, the backup lamp 1
causes and relay is defective.
in normal state without turning starting switch ON.
Defective backup lamp 2 relay Between (1) and (2) 200 – 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
relay is defective.
Between (1) and (2) 200 – 400 z
Defective FR pressure select
5
When FR pressure select relay (L101) is replaced with a relay of the
same type, if the condition becomes normal, the FR pressure select
relay is defective.
WA200-6 63

Max. 1 z
Max. 1 z
Max. 1 z
Reference: Following 4 items are circuits for turning backup alarm
ON with directional lever in R position.
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
ness ground tance
6
(Disconnection or defective Reference: Following 4 items are circuits for turning backup alarm
contact in connector) ON when HST controller outputs signal to reverse solenoid.
Max. 1 z
Possible Max. 1 z
causes and
in normal state
Max. 1 z
ground tance
Wiring harness between B03 (female) (2) – Resis-
Max. 1 z
ground tance
Wiring harness between fuse box FS1 No. 5 Resis-
Max. 1 z
– L24 (female) (4), (5) tance
Reference: If above wiring harness is disconnected, when directional
switch is set in R and backup alarm turned ON and then directional
lever or directional switch is set in position other than R, backup
alarm may not go OFF.
Resis-
box (FS2) – L109 (female) (3), (1) – circuit Min. 1 Mz
tance
7
(Contact with ground circuit) Wiring harness between L109 (female) (5) –
Resis-
R22 (female) (2), – R23 (female) (2), – circuit Min. 1 Mz
tance
Min. 1 Mz
R22 (female) (2), – R23 (female) (2), – circuit Voltage Max. 1 V
64 WA200-6
WA200-6 65
E-15 Horn does not sound or it keeps sounding 1

Contents of
Horn does not sound or it keeps sounding.
trouble
Related
—
information

1
Defective horn relay (L116) Between (1) and (2) 200 – 400 z
2
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective L13 horn switch L13 (male) Horn switch Resistance
3
(Internal trouble)
Between (1) and ON Max. 1 z
ground OFF Min. 1 Mz
Possible and carry out troubleshooting. (Disconnect connector and mea-
causes and sure on female side)
standard value F01, F02 Horn switch Voltage
in normal state
Defective horn Between F01 (1) and ON Max. 1 V
4 (2)
(Internal trouble) OFF 20 – 30 V
Between F02 (1) and ON Max. 1 V
(2) OFF 20 – 30 V
a If horn does not sound normally under above condition, it is
defective.
Max. 1 z
Max. 1 z
5
F01 (female) (1), – F02 (female) (1) tance
Wiring harness between F01 (female) (2) – Resis-
Max. 1 z
F02 (female) (2) – ground tance
Wiring harness between steering wheel horn Resis-
Max. 1 z
switch – ground tance
66 WA200-6

Resis-
box (FS2) – L116 (female) (1), (3), – circuit Min. 1 Mz
tance
6
Possible (Contact with ground circuit) Wiring harness between L116 (female) (5) –
Resis-
causes and F01 (female) (1), – F02 (female) (1), – circuit Min. 1 Mz
tance
standard value branch end and ground
in normal state Wiring harness between L116 (female) (2) – Resis-
Min. 1 Mz
and carry out troubleshooting while not pressing horn switch.
F01 (female) (1) or F02 (female) (1) and Voltage Max. 1 V
ground
WA200-6 67
E-16 Alarm buzzer does not sound or it keeps sounding 1

Contents of
• Alarm buzzer does not sound or it keeps sounding.
trouble
• Disconnection or ground fault in alarm buzzer output circuit
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: MONITOR PANEL 40952, D-OUT-0).
• If failure code is indicated, carry out troubleshooting for it first.

1
box FS1 (See cause 4.)
• Remove the buzzer then connect +24 V to L46 (male) (1) and
Defective alarm buzzer GND to L46 (male) (2).
2
(Internal trouble) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
causes and Disconnection in wiring har- without turning starting switch ON.
standard value ness Wiring harness between fuse No. 5 of fuse Resis-
in normal state 3 Max. 1 z
(Disconnection or defective box FS1 – L46 (female) (1) tance
Max. 1 z
Ground fault in wiring harness Resis- Min.
4 box FS1 – L46 (female) (1), – circuit branch
(Contact with ground circuit) tance 1 Mz
end and ground
Wiring harness between L46 (female) (2) – Resis- Min.
L24 (female) (14) and ground tance 1 Mz
• When above 1 – 4 are normal, failure on the machine monitor can
be suspected.
68 WA200-6
WA200-6 69
E-17 Air conditioner does not operate or stop 1

Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting applicable only to the power supply and GND circuit between the air
Related
conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual
information
for the air conditioner.

Defective No.1 and No.2 fuses
of fuse box (FS2) or defective
If the fuse is burn, the circuit probably has a grounding fault, etc.
1 5A and 15A fuses of the main
(See cause 2.)
circuit in the air conditioner
unit.
• When fuse No. 1 of fuse box (FS2) is blown
box A – 5A fuse of air conditioner main cir- Resis- Min.
cuit, – 15A fuse in the air conditioner and tance 1 Mz
ground
• When fuse No. 1 of fuse box (FS2) is broken
Wiring harness between fuse No. 1 of fuse Resis- Min.
box A – compressor clutch relay and ground tance 1 Mz
Wiring harness between compressor clutch Resis- Min.
Grounding fault in power relay – E10 (female) (2) and ground tance 1 Mz
2 supply wiring harness
(Contact with ground circuit) a Prepare with starting switch OFF, then carry out troubleshooting
causes and • When 5A fuse of the air conditioner unit main circuit is broken
standard value Wiring harness between 5A fuse of air condi-
in normal state tioner unit main circuit – C48 (female) (7), – Resis- Min.
pressure switch, – blower OFF relay primary tance 1 Mz
side and ground
• When 15A fuse of the air conditioner unit is broken
Wiring harness between 15A fuse of air con- Resis- Min.
ditioner unit – blower OFF relay and ground tance 1 Mz
Wiring harness between blower OFF relay – Resis- Min.
blower motor and ground tance 1 Mz
C48 Starting switch Voltage
Defective A/C control panel ON 20 – 30 V

Between (7) and (1)
power supply and disconnec- OFF Max. 1 V
3 tion of GND wring harness a Prepare with starting switch OFF, then carry out troubleshooting
(disconnection or defective without turning starting switch ON.
Max. 1 z
box (FS2) – C48 (female) (7) tance
Wiring harness between C48 (female) (1) – Resis-
Max. 1 z
ground tance
70 WA200-6

Blower OFF relay,
Starting switch Voltage
pressure switch
Blower OFF relay ON 20 – 30 V
(15A fuse line) and
ground OFF Max. 1 V
Blower OFF relay (5A ON 20 – 30 V

fuse line of main cir-
cuit) and ground OFF Max. 1 V
Pressure switch ON 20 – 30 V
Possible
Disconnection in wiring har- (5A fuse line of main
causes and OFF Max. 1 V
ness of relay power supply circuit) and ground
standard value 4
in normal state (Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact in connector) without turning starting switch ON.
Resis-
box (FS2) – blower OFF relay (on the 15A Max. 1 z
tance
fuse line)
Resis-
box (FS2) – blower OFF relay (on the 5A fuse Max. 1 z
tance
line of main circuit)
Resis-
box (FS2) – pressure switch (on the 5A fuse Max. 1 z
tance
line of main circuit)
Wiring harness between pressure switch – Resis-
Max. 1 z
compressor clutch relay tance
WA200-6 71
72 WA200-6
E-18 The KOMTRAX system does not work properly 1

Trouble • The KOMTRAX system does not work properly.
• If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
• A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.

a Turn the starting switch OFF, then carry out troubleshooting.
LED (1) Normal state
LED-A1 ON
1 Defective power supply a Prepare with starting switch OFF, then carry out troubleshooting
L80 Signal Voltage
Between (39), (40) – Constant power sup-
20 – 30 V
(37) and (38) ply
a Turn the starting switch ON, then carry out troubleshooting.
2 Defective communication LED (2) Normal state
LED-A2 ON
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
3 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Possible Between (36) and
causes and Starting switch ACC 20 – 30 V
(37), (38)
standard value
Between (28) – (37),
in normal state Alternator R 20 – 30 V
(38)
a Turn the starting switch ON, then carry out troubleshooting.
During cranking: Blinking
LED-C3
Other than above: OFF
Defective starting switch C and carry out troubleshooting.
4
signal L80 Signal Voltage
Between (10) and (9) S-NET 6–9V
During cranking:
Between (27) and 20 – 30 V
Starting switch C
(37), (38) Other than above:
Max. 1 V
a Turn the starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
5 a Prepare with starting switch OFF, then carry out troubleshooting
state
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
WA200-6 73

a Turn the starting switch ON, and carry out troubleshooting.
6 Number of unsent mails LED (12) Normal state
Possible 7 segments 0–9
causes and a Turn the starting switch ON, and carry out troubleshooting.
standard value
in normal state
Defective GPS positioning Dot ON
7
status
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
74 WA200-6
LED display L80 connector
LED lamps for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output state)
3. LED-C3 (State of C signal)
4. LED-C4 (CAN state)
7-segment and dot displays for CPU
7. 7 segments (Number of unsent mails)
8. Dot (GPS positioning state)
WA200-6 75
SEN03744-00

© 2007 KOMATSU
All Rights Reserved
76
SEN03745-00
WA200-6
WA200-6 70001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 3
Failure code and cause table .......................................................................................................................... 6
H-1 The machine does not start...................................................................................................................... 8
H-2 The travel speed is slow........................................................................................................................... 9
H-3 The traction force is weak ...................................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively............................................................11
H-5 Speed range is not shifted...................................................................................................................... 12
H-6 The steering wheel does not turn........................................................................................................... 13
H-7 The steering wheel is heavy................................................................................................................... 14
H-8 Steering wheel shakes or jerks .............................................................................................................. 15
H-9 Machine deviates naturally to one side when traveling.......................................................................... 15
H-10 The brake does not work or does not work well................................................................................... 16
H-11 The brake is not released or is dragged ............................................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................................ 18
WA200-6 1
H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................................. 20
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily .................. 21
H-19 The bucket does not tilt back................................................................................................................ 22
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24
H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) ................. 24
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...................... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25
H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27
2 WA200-6
Method of using troubleshooting chart 1

This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable troubleshooting, put a check against the item.
cause.Keeping the content of the questions in a When carrying out the troubleshooting,
mind, read the matrix and proceed with Step 2 check the easier items first. It is not neces-
and Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Ask the operator and check the following points. Remedy
No.
q Did the problem suddenly start? Diagnosis
o Related equipment broken Steering does not turn in both directions (left
1
q Was the steering wheel heavy before? and right)
o Wear of related parts, defective seal Steering turns only in one direction (left or
2
right)
Step 2. Checks before troubleshooting Steering is heavy when turned in both direc-
q Before measuring the oil pressure or starting 3
tions (left and right)
the troubleshooting, confirm the checks before Steering wheel is heavy in one direction (left
starting items, check for leakage of oil, or for 4
or right)
loose bolts. This will prevent wasting time
5 Work equipment moves
when troubleshooting. The items given under
“Checks before troubleshooting” are checks
that are particularly important to make about 2. Find the matching cause in the Cause column.
the condition of the machine before starting the In the same way as in Step 2), if a problem is
actual troubleshooting. found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diag-
Example: Checks before starting troubleshoot- nosis item 2 in the same diagram below the
ing cause is (c) or (e).)
q Is oil level and type of oil in hydraulic tank cor- When there is one Q mark:
rect? Carry out troubleshooting for the other items
q Is there any oil leakage from steering valve or marked with Q in the same Cause column to
demand valve? check if the problem occurs, then make
q Is steering linkage adjusted properly? repairs.
When there are two Q marks:
Go to Step 3) to narrow down the cause.
WA200-6 3
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the Cause column. take the action given in the remedy line.
In the same way as in Step 2), if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the ×: Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
(b) or (e).)
5. Narrow down the causes.

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1) and Step 3).
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are (c) or (e), and the causes
in Diagnosis item 5 are (b) or (e), so
Cause (e) is the common cause.)
4 WA200-6
WA200-6 5
Failure code and cause table 1

Part causing problem HST HST
HST pump
motor 2 motor 1
Pump body (Charge pump end)

Pump body (Piston pump end)
Angle stopper control solenoid

Mode selector solenoid valve
Angle stopper solenoid valve

High pressure cut-off valve
Directional solenoid valve

High pressure relief valve
Low pressure relief valve
Inching valve linkage

(Charge relief valve)
Inching valve
Motor body
Motor body
DA valve
Damper
(SOL a)
(SOL b)
valve
Failure Code
Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q
Does not travel forward (reverse is normal) Q Q
The machine does not start at reverse (Forward is normal) Q Q
Speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q
HST related
The travel speed is slow at forward (Reverse is normal) Q Q

The travel speed is slow at reverse (Forward is normal) Q Q
The traction force is weak in both forward and reverse Q Q Q Q Q Q
The traction force is weak at forward (Reverse is normal) Q
The traction force is weak at reverse (Forward is normal) Q
Engine stalls when traveling or engine speed drops excessively Q Q Q
Speed range is not shifted Q Q
The steering wheel does not turn
Steering wheel
The steering wheel is heavy
There is play in steering wheel or excessive shock

Machine deviates naturally to one side when traveling
The brake does not work or does not work well
Brake
The brake is not released or is dragged

The lift arm does not rise or lower Q Q
The lift arm moves slowly or the lift arm rising force is insufficient Q
When the lift arm is rising, the lift arm comes to move slowly at
specific height
The lift arm cylinder cannot be hold down the bucket
(The bucket rises in the air)
Hydraulic drift of the lift arm occurs often
Work equipment system
The lift arm wobbles during operation

When the control lever is switched from “HOLD” to “RAISE”, the lift
arm falls temporarily
The bucket does not tilt back Q Q
The bucket moves slowly or the tilting-back force is insufficient Q
The bucket comes to operate slowly in the midst of tilting-back
The bucket cylinder cannot be hold down to bucket
Hydraulic drift of the bucket occurs often
The bucket wobbles during travel with load
(The work equipment valve is set to “HOLD”)
When the control lever is switched from “HOLD” to “TILT”, the bucket
falls temporarily
The control levers of the lift arm and bucket do not move smoothly
and heavy
ECSS does not operate but pitches and bounces
(if equipped)
ECSS
ECSS does not move at all
Fan revolution is abnormal (Fan sound/vibration is abnormally large

or engine overheats)
Hydraulic
fan
Fan always revolves in reverse
6 WA200-6
Clutch solenoid
Clutch
Q Q
Q Q
Transfer
Q Q Q
Q Q Q
WA200-6
Work equipment and steering pump
Q
Q
Q
Q
Q
Q
Q
Brake pump
Q
Orbit-roll
Q
Priority valve
Q
Q
Q
Q
Q
40 Troubleshooting
Relief valve
Q Q Q
Q Q Q
Safety valve
Steering valve
Steering cylinder
Q
Q
Q
Tire inflation pressure
Q Q Q
Accumulator charge valve
Brake valve
Slack adjuster
Brake disc and plate
Axle
Brake piston
Q Q Q
Wheel brake linkage
Q Q Q Q Q Q
Main relief valve
Q
Q
Q
Lift arm spool
Q
Q
Q Q
Q Q
Q Q
Bucket spool
Q
Q
Suction and safety valve
Q
Q Q
Q Q
Q Q
Q
control valve
Work equipment
Suction valve
Lift arm cylinder
Q Q
Q
Q
Q
Q
Q
Bucket cylinder
Q
Q
Q
Q
Q
Lift arm PPC valve
Q
Q
Q
Bucket PPC valve
Q Q
Q
Q
Q
Bypass valve
Q
2-way restrictor valve
Cushion valve
Q Q
ECSS solenoid valve

Accumulator
Q Q
Q
Fan pump
Fan motor
Q
Charge valve
Q Q Q
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN03745-00
Work equipment system Brake Steering wheel HST related

H-1 The machine does not start 1

Ask the operator about the following: Cause
Has the machine come not start suddenly?
HST motor 2
HST motor 1
q
HST pump
Damper
o Breakage of HST pump and motor related
Others
equipment
q Was there any problem of not traveling before?
o Internal wear of HST pump and motor related
a b c d e f g h i j k l m n o
equipment, defective seal
Low pressure relief valve (Charge relief valve)

Inspection before diagnosis
q Are the oil level in the hydraulic tank and the oil type
appropriate?
q Is inching valve linkage properly adjusted?

Is the any external oil leak found around the hydraulic

q
piping, pump and motor?


Clutch solenoid
Inching valve
Motor body
Motor body
DA valve
Transfer
Damper
Clutch
E E E E E E E E E E E E E E E
Remedy
No. X X X X X X X X X X X X X X X
Diagnosis A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Does not travel forward (reverse is normal) Q Q
3 Does not start at reverse (Forward is normal) Q Q
Does not travel forward or in reverse, motor makes sound of Q Q Q
4
rotation
8 WA200-6
H-2 The travel speed is slow 1

q Did the travel speed suddenly become HST pump HST motor 2
HST
Others
slower? motor 1
o Breakage of HST pump and motor a b c d e f g h i j k l m n o
related equipment
q Was there any problem of travel speed
Low pressure relief valve (Charge relief valve)

becoming slower before?
o Internal wear of HST pump and
Mode selector solenoid valve (SOL a)
Angle stopper solenoid valve (SOL b)

motor related equipment, defective
Angle stopper control solenoid valve

seal


q Are the oil level in the hydraulic tank and

the oil type appropriate?
q Is the inching valve linkage adjusting
Clutch solenoid
appropriate?
Inching valve
Motor body
Motor body
q Is the any external oil leak found around
DA valve
the hydraulic piping, pump and motor?
Clutch
E E E E E E E E E E E E E E E
Remedy
No. X X X X X X X X X X X X X X X
Diagnosis A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
The travel speed is slow at forward (Reverse is nor- Q Q
2
mal)
The travel speed is slow at reverse (Forward is nor- Q Q
3
mal)
Maximum travel speed in both forward and reverse
4 Q
is approx. 4 km/h
Maximum travel speed in both forward and reverse Q
5
is approx. 18 km/h
Abnormal sound comes from motor in both forward
6 Q Q
and reverse when travel speed is 10 km/h or more
WA200-6 9
H-3 The traction force is weak 1

a When the travel speed is slow, carry out troubleshooting for Cause
H-2 first. HST HST HST
Others
pump motor 2 motor 1
a b c d e f g h i j
Inclination control solenoid valve


Clutch solenoid
Inching valve
Motor body
Motor body
Transfer
Clutch
E E E E E E E E E E
Remedy
No. X X X X X X X X X X
Diagnosis A
1 The traction force is weak in both forward and reverse Q Q Q Q Q Q Q Q Q
2 The traction force is weak at forward (Reverse is normal) Q
3 The traction force is weak at reverse (Forward is normal) Q
The traction force is weak in both forward and reverse, but maxi-
4 Q Q Q
mum travel speed is reached the line.
10 WA200-6
H-4 Engine stalls when traveling or engine speed drops excessively 1

q Was there any problem before? HST HST
Others
o Dirt in HST pump, motor related equipment pump motor 2
a b c
Inclination stopper solenoid valve (SOL b)

q Is the any external oil leak found around the hydraulic piping, pump and
motor?

DA valve
E E E
Remedy
No. X X X
Diagnosis
1 Engine stalls when traveling or engine speed drops excessively Q Q Q

2 Machine moves when the directional lever is at F or R and engine is at Lo Q
WA200-6 11
H-5 Speed range is not shifted 1

a If the speed range switch and the monitor display do not match, check Cause
the electrical wiring. HST HST
a When the travel speed is slow, carry out troubleshooting for H-2 first. Others
motor 2 motor 1
a b c d
Inclination stopper solenoid valve (SOL b)
Clutch solenoid
Clutch
E E E E
Remedy
No. X X X X
Diagnosis
1 Speed range is not shifted Q Q Q Q
12 WA200-6
H-6 The steering wheel does not turn 1

q Did the problem suddenly start? Hydraulic
Others
o Breakage of steering related equipment pump
q Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective seal
Internal defective steering cylinder (Defective piston seal)

Defective hydraulic pump or PTO
Steering pump and switch pump
q Are the oil level in the hydraulic tank and the oil type appropriate?
q Has the lock bar been removed from frame?
Priority valve
Emergency steering valve (*1)

2-way restrictor valve
Relief valve
Orbit-roll
Steering
Spool
E E E E
Remedy
No. X X X X X X X
Diagnosis
1 Steering wheel does not turn in both directions (left and right) Q Q Q Q Q Q
2 In condition in Item 1, movement of work equipment is abnormal Q
3 In condition in Item 1, movement of work equipment is normal Q
4 Steering wheel turns only in one direction (left or right) Q Q Q
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no pressure Q
7 Emergency steering does not function in both directions (left and right) Q
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormal-
ity is felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
*1. This warning is given only when the emergency steering is installed.
WA200-6 13
H-7 The steering wheel is heavy 1

q Did the problem suddenly start? Hydraulic
Valve Others
o Breakage of steering related equipment pump
q Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective
The steering pump is defective The hydraulic pump is defective

seal
Clogging of hydraulic oil return filter, defective bypass valve

Internal defective steering cylinder (Defective piston seal)
q Are the oil level in the hydraulic tank and the oil type appropri-
ate?
q Is there any abnormality in Orbit-roll, steering column linkage?
Priority valve
q Is the any external oil leak found around the hydraulic piping,
valve and cylinder?
q Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
q Is the tire inflation pressure correct?
Check for abnormalities
Orbit-roll internal defect

q Measure operating effort of steering wheel and time taken to
Clogging of oil cooler

turn steering, and check standard judgement value table to
see if there is any abnormality.
Relief valve
Spool
E E E E E E E
Remedy
No. X X X X X X X
Diagnosis A C C
1 Steering wheel is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering wheel is heavy when turned in one direction (left and right) Q Q
Steering wheel is heavy particularly when engine is running at low Q Q Q Q
3
speed
4 Lift arm lifting speed is slow when engine is running at full speed Q Q
5 Steering wheel is heavy and there is jerking Q Q
6 Hydraulic oil overheats Q Q Q
7 Oil pressure of steering circuit is low or there is no pressure Q Q
8 Pressure rises in return piping of steering cylinder Q
14 WA200-6
H-8 Steering wheel shakes or jerks 1

Checks before troubleshooting Cause
q Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder Valves
q Is there any play in the center hinge pin bearing or steering cylinder pin or a b c d
bushing?
Defect inside steering cylinder (inside surface of cylinder, piston seal, nut, bolt)
q Is there any variation in the tire inflation pressure?
q Is the steering wheel play correct?
Check for abnormalities

q Operate at a safe place and check how the steering wheel shakes and under
what conditions.
a In cases where the steering wheel is heavy but does not shake, go to “H-7 The
steering wheel is heavy”.
Defective 2-way restrictor valve
Defective cushion valve

Defect inside Orbit-roll
E E E
Remedy
No. X X X X
Diagnosis
1 Chassis shakes when traveling on rough road surface Q Q Q

2 Shakes when steering is suddenly turned during operation or travel Q Q Q
3 Chassis shakes when accelerating during travel operations Q Q Q
4 Chassis shakes when engine is started Q
5 Excessive shock when steering wheel is turned back Q
H-9 Machine deviates naturally to one side when traveling 1

Causes: Defective steering
q Defective operation of safety valve
q Oil leakage inside steering cylinder
q Variation in tire inflation pressure
WA200-6 15
H-10 The brake does not work or does not work well 1
q Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Defective seal of accumulator piston, insufficient gas pressure

q Has the brake come not to work gradually?
Metal contact due to complete wear of brake lining in axle

o Wear of lining and disc, defective seal
Defective operation of accumulator charge valve

q Is the oil level in the hydraulic tank appropriate?
q Is the play of brake pedal appropriate?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
q Oil leak from brake tube and connector, deformation of
tube.
q Tire air pressure and state of tire tread.
Defective brake pump (For charge)

Defective brake piston seal in axle
Check abnormality
Mixing of air in brake circuit

q Measure the braking force and check referring to the stan-
Defect inside brake valve

dard value table if the brake does not work practically.
Defective slack adjuster
Defective brake linkage

E E E E E E E
Remedy
No. X X X X X X X X X A
Diagnosis
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q
2 When the brake pedal is stepped on, a strong resistance is felt Q Q
When the brake works, an abnormal noise occurs from the axle Q Q
3
brake
When the four wheels are jacked up, the axle is placed on a table
4 and the brake is applied at the first forward speed, only a specific Q Q Q Q
wheel rotates
An airflow is observed in bleeding air from brake circuit, and the Q
5
brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q
7 Much metal powders are mixed in the axle oil Q
The brake pedal leg-power and stroke are normal, but the brake
8 Q Q Q Q Q Q Q Q Q
does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
10 The accumulator is not charged, and a buzzer sounds Q Q Q
11 The brake works after some time lag Q Q Q
16 WA200-6
H-11 The brake is not released or is dragged 1

q Has the brake pedal returned completely? a b c d
q Is the parking brake released completely?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Check abnormality
Defective brake piston seal in axle

q Abnormal heat of brake.
q Does the machine travel smoothly inertia on a level ground?
Defective slack adjuster

E E E E
Remedy X X X X
No.
Diagnosis
1 The brake pedal is released, but the brake is still applied Q Q Q Q
When the brake pedal is released, oil is drained from the air bleeder, the circuit oil pressure
2 Q Q
drops and the brake is released
When the four wheels are jacked up, the axle is placed on a table, the engine is stopped, the
3 Q Q Q
parking brake is released and the tires are rotated by hand but a specific tire hardly rotates
WA200-6 17
H-12 The lift arm does not rise or lower 1

q Has the lift arm come not to work suddenly? Work
Priority HST PPC
o Seizure or breakage of each equipment Tank to Pump
valve pump valve
equip- Cylinder
Did any abnormal noise occur at the time ment valve
(And where)? a b c d e f g h i j
q Was there the phenomenon that the lift arm
Clogging of pump suction port or mixing of much air in oil

worked slowly?
o Wear of parts or deformation of spring

Is the oil level in the hydraulic tank appropriate?
Breakage inside valve body (Lift arm spool)

q
q Is the stroke of the lift arm control lever appro-
Defective operation of main relief valve
Damage of lift arm cylinder piston seal

priate?
Defective low-pressure relief valve

q Is the engine speed appropriate?
Defective work equipment pump

Defective HST charge pump
Defective operation of spool

Defective steering pump
C E E E E E E
Remedy E X X X X X X X X X
No.
Diagnosis
The bucket cannot operate and the lift arm cannot
1 Q Q Q Q Q Q Q Q
rise
2 The bucket operates but the lift arm cannot rise Q Q
The lift arm can rise without load but cannot rise
3 Q Q Q Q
when loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
When the engine is at full throttle, the steering opera- Q Q
6
tion is heavy and slow
18 WA200-6
H-13 The lift arm moves slowly or the lift arm rising force is insufficient1
Inspection before diagnosis Cause
q Is the stroke of the lift arm control lever appropri- Tank to Priority HST PPC Work equipment
Cylinder
ate? Pump valve pump valve valve
a b c d e f g h
Check of abnormality
Defective operation or improper adjustment of main relief valve

q Rising force and speed problem are closely
related, and this problem occurs as insufficient ris-

ing speed at first. Measure the lift arm rising speed
when the lift arm is loaded and make sure referring
Wear or breakage inside valve body (Lift arm spool)

Defective work equipment pump and steering pump
to the criterion table that the speed is abnormal.
Damage of lift arm cylinder piston seal

Defective low-pressure relief valve

C E E E E A E
Remedy E X X X X X X X
No.
Diagnosis
The bucket tilting force and speed are abnormal, and
1 Q Q Q Q Q
the lift arm rising speed is slow
The bucket tilting force and speed are normal, and the
2 Q Q Q
lift arm rising speed is slow
When the oil temperature rises in item 1, the lift arm Q Q
3
speed becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
The relief oil pressure from the relief valve of the work
6 Q
equipment valves is low
The relief oil pressure from the relief valve of the work
7 Q
equipment valves is too high
WA200-6 19
H-14 When rising, the lift arm comes to move slowly at specific height 1
q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-13. The lift arm moves slowly or the lift arm
rising force is insufficient.”
H-15 The lift arm cylinder cannot hold down the bucket (The bucket
rises in the air) 1
See “H-13. The lift arm moves slowly or the lift arm rising force is insufficient.”

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
q Oil leak from lift arm cylinder piston seal
H-16 Hydraulic drifts of the lift arm occur often 1

Ask the operator about the following:
q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts

q Is the lift arm spool at the neutral position? o The spool detent is defective
Diagnosis and Cause

q Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylin-
der packing is defective
H-17 The lift arm wobbles during operation 1

The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the “HOLD” position.
Diagnosis and Cause

Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see “H-16. Hydraulic drifts of the lift arm occur
often.”
2. When the lift arm cylinder cannot lift the machine, see “H-15. The lift arm cylinder cannot hold down the
bucket.”
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vac-
uum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
20 WA200-6
H-18 When the control lever is switched from “HOLD” to “RAISE,” the
lift arm falls temporarily 1
Check of Phenomenon
q When the control lever is switched from “HOLD” to “RAISE” gradually at low idle of the engine, the lift
arm falls temporarily due to its own weight. When the control lever is completely set to “RAISE,” the lift
arm returns to normal.
Cause
q Improper adhesion of lift arm spool check valve of the work equipment valve
WA200-6 21
H-19 The bucket does not tilt back 1

q Has the bucket come not to work suddenly Priority HST PPC Work equip- Cylin-
Tank to Pump
o Seizure or breakage of each equip- valve pump valve ment valve der
ment a b c d e f g h i j
Did any abnormal noise occur at the
The HST charge pump (which is used as PPC pump, too) is defective
time (And where)?
q Was there the phenomenon that the bucket
worked slowly?
o Wear of parts or deformation of

spring

q Is the stroke of the bucket and lift arm con-
trol levers appropriate?
Breakage inside valve body (Bucket spool)

The low-pressure relief valve is defective
Defective operation of main relief valve
Damage of bucket cylinder piston seal

The hydraulic pump is defective
The steering pump is defective
The spool is defective
C E E E E A
Remedy E X X X X X X X X
No.
Diagnosis
The lift arm cannot operate and the bucket can-
1 Q Q Q Q Q Q Q
not tilt back
The bucket can lift the machine but cannot tilt
2 back, or the lift arm operates but the bucket can- Q Q Q
not tilt back
The bucket can tilt back without load but cannot
3 Q Q Q
in digging or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of bucket cylinder Q Q
When the engine is at full throttle, the steering
6 Q Q
operation is heavy and slow
22 WA200-6
H-20 The bucket moves slowly or the tilting-back force is insufficient 1

Inspection before diagnosis Cause
q Is the stroke of the bucket control lever Tank to Priority HST PPC
Work equipment valve Cylinder
appropriate? Pump valve pump valve
q Seizure of work equipment linkage a b c d e f g h i
bushing (Does any abnormal noise
Defective operation or improper adjustment of main relief valve

occur?)

The hydraulic pump and the steering pump are defective
Check of abnormality
Defective operation of safety valve (With suction valve)

q Make sure in an actual operation that
Wear or breakage inside valve body (Bucket spool)

the tilting-back force is insufficient.
Defective operation of low-pressure relief valve

q Measure the operating speed of the
bucket, and make sure referring to the
criterion value table that the speed is
Damage of bucket cylinder piston seal

abnormal
on bucket cylinder bottom side

C E E E E A E
Remedy E X X X X X X X X
No.
Diagnosis
The lift arm rising force and speed are
1 abnormal, and the bucket tilting force and Q Q Q Q Q
speed are abnormal
The lift arm rising force and speed are nor-
2 mal, and the bucket tilting force and speed Q Q Q Q
are abnormal
When the oil temperature rises in item 1, the
3 Q Q
bucket speed becomes worse
The hydraulic pump is causing an abnormal Q Q
4
noise
5 Large hydraulic drift of bucket cylinder Q Q Q
The relief oil pressure from the relief valve of
6 Q Q Q
the work equipment valves is low
The relief oil pressure from the relief valve of
7 Q
the work equipment valves is too high
WA200-6 23
H-21 The bucket comes to operate slowly in the midst of tilting-back 1

q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
q For other abnormal phenomena during bucket operation, see “H-20. The bucket moves slowly or the tilt-
ing-back force is insufficient.”
H-22 The bucket cylinder cannot hold down the bucket 1

See “H-20. The bucket moves slowly or the tilting-back force is insufficient.”

q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
q Oil leak from bucket cylinder piston seal
H-23 Hydraulic drifts of the bucket occur often 1

Ask the operator about the following:
q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts

q Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is
defective
Check of Abnormality
q Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of bucket spool
H-24 The bucket wobbles during travel with load

(The work equipment valve is set to “HOLD”) 1
q Pin of work equipment linkage and “play of bushing” (Is any abnormal noise heard?)
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal
phenomena, refer to diagnoses for relevant abnormal phenomena.
24 WA200-6
H-25 When the control lever is switched from “HOLD” to “TILT,” the
bucket falls temporarily 1
Check of Phenomenon
q When the control lever is switched from “HOLD” to “TILT” gradually at low idle of the engine, the bucket
falls temporarily due to its own weight. When the control lever is completely set to “TILT,” the bucket
returns to normal.
Cause
q Improper adhesion of bucket spool check valve of the work equipment valve
H-26 The control levers of the lift arm and bucket do not move smoothly
and heavy 1
Check of Abnormality Cause
q Refer to the criterion value table and check if the lever operating efforts are large practically. PPC
valve
a

Remedy C
No. E
Diagnosis
1 Becomes heavy in some places during operation regardless of oil pressure and oil temperature Q
2 Becomes heavy overall during operation regardless of oil pressure and oil temperature Q
WA200-6 25
H-27 The ECSS does not operate and machine pitches and bounces 1
Check the following points with the operator. Cause
q Did the machine starts pitching and bouncing sud- Solenoid
Accumulator Controller Sensor
denly? valve
o Breakage of related device a b c d
Did abnormal sound come out when the machine
Gas leakage from accumulator or defective seal

started pitching and bouncing? From what part did
the abnormal sound come out?
q Did the machine starts pitching and bouncing gradu-
ally?
o Wear of related device or defective seal
Defective travel speed sensor

Malfunction of solenoid valve
Check before troubleshooting
q Check that the hydraulic tank is filled with oil of a
Malfunction of controller
proper type up to a proper level.
q Check that the ECSS switch is set properly.
Remedy
No. X X X X
Troubleshooting
Travel speed to start operation of ECSS (5 km/h) changes
1 Q Q
largely
2 ECSS does not work while machine is loaded Q Q
3 ECSS does not work while machine is empty Q Q
Lift arm lowers more than 30 cm at maximum when ECSS Q
4
operated while machine is loaded
5 ECSS does not work at all Q Q Q Q
26 WA200-6
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats) 1
Check the following with the operator. Cause
q Did the fan start making the abnormal sound sud- Tank to Charge
Fan motor Others
denly? Pump valve
o Damage of the devices related to the fan and a b c d e f g h i j k
fan motor
q Did the engine overheat after the fan had started
making the abnormal sound?
o Internal wear of the devices related to the fan
pump and fan motor, lowering of sealing per-
Clogging or sucked air on pump suction side

formance or dirt
Check for abnormality
Seized forward-reverse selector valve

q Measure the fan speed to check for abnormality.
Malfunction of suction safety valve

Seized brake circuit selector spool
Malfunction of EPC solenoid valve
Lowering of engine performance

Seized ON/OFF solenoid valve
Check before troubleshooting
q Check the level and type of the oil in the hydraulic
Malfunction of relief valve
Malfunction of controller
tank.
q Check the hydraulic hoses, pump and motor for oil
Defective fan motor

Defective fan pump
leakage.
q Check the fan for damage.
(Note): If “Lowering of engine performance” is judged, go to the

troubleshooting for the engine system (S mode).
C Note
Remedy E E E E E E E
No.
Troubleshooting X X X X X X X X X
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q
WA200-6 27
SEN03745-00

© 2007 KOMATSU
All Rights Reserved
28
SEN03746-00
WA200-6
WA200-6 70001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting charts .......................................................................................................... 2
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
S-16 Vibration is excessive ........................................................................................................................... 23
WA200-6 1
Method of using troubleshooting charts 1

The troubleshooting chart consists of the “ques-
tions”, “check items”, “causes”, and “troubleshoot-
ing” blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
2 WA200-6
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the “causes“, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
WA200-6 3
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
4 WA200-6
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
WA200-6 5
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Insufficient supply of fuel
Defective alternator (generator section)

q
Defective alternator (regulator section)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

Improper selection of fuel
Defective or deteriorated battery

q
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element
Clogged fuel filter, element

fuel injection timing electrically. Accordingly, even if the
Worn piston ring, cylinder

starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
w w Q Q
Maintenance Manual
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
w
indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not w
While engine is cranked flow out
with starting motor,
Much fuel returns from the injector w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display q
of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Failure codes [CA559] and [CA2249] in the display of code
6 WA200-6
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Seized parts inside engine
o See “S-4 Engine stops during operations”
Defective or deteriorated battery
Defective steering circuit wiring

q Defective electrical system
q Problem in drive devices on applicable machine side
Broken flywheel ring gear
Defective starting switch

o Carry out troubleshooting for devices on applicable machine
Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in E-mode

There is not voltage (20 – 30 V) between battery relay terminal B and q
terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected, q

engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out q
engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are connected,
engine does not start q
When terminal at safety switch and terminal B at starting motor are

q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
WA200-6 7
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke comes
Defective operation of overflow valve (Does not close)

out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump IMV (IMA)
Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
Fuel is leaking from fuel piping w
Check items

If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked with flow out Q Q w Q
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in
q q
display of code
Carry out troubleshooting according to “Abnormality in supply pump IMV (IMA) (*2)” in
q
display of code
Inspect pressure relief valve directly q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy

8 WA200-6
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

q Insufficient supply of fuel
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

q
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Maintenance Manual w w

When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
If air bleeding plug of fuel filter is removed, fuel does not

While engine is cranked with flow out Q w
starting motor,
If spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Inspect fuel filter directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display
q
of code
Coolant temperature gauge does not indicate normally q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Failure code [CA559] and [CA2249] in the display of code
WA200-6 9
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Improper selection of fuel
q Controller is controlling in derate mode

(limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray


Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance
Manual w w

Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of
q
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Remedy
10 WA200-6
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Internal parts of engine seized
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Defective engine controller power supply wiring

q Problem in hydraulic pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Defective starting switch wiring

Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Abnormal noise was heard and engine
w w w w Q w Q w w
stopped suddenly
Condition when engine w Q Q Q Q
Questions
Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation w w
and Maintenance Manual
Fuel level monitor indicates low level w
Rust and water are found when fuel tank is drained w w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply
q q
pump (*1)” in display of code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
q
is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
—
WA200-6 11
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness


Degree of use of machine Operated for long period E
Occurs at a certain speed range Q Q
Questions
Occurs at low idle Q Q Q Q Q

Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to “Abnormality in Ne speed sensor (*1)” in display of code q
Carry out troubleshooting according to “Abnormality in Bkup speed sensor (*2)” in display of code q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Failure code [CA689] in the display of code

*2: Failure code [CA778] in the display of code
12 WA200-6
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Insufficient supply of fuel
Defective installation of boost pressure sensor

q
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See “S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)“

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
Replacement of filters has not been carried out according to Operation and w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red w w
Air breather hole of fuel tank cap is clogged w w
Output becomes insufficient after short stop of operation w
Black w w
When exhaust manifold is touched immediately after starting engine, temperature of w w
some cylinders is low
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in
q
display of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in boost pressure sensor (*2)”
q
in display of code
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

WA200-6 13
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head



o See “S-14 Coolant temperature becomes too high
(Overheating)“

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler

electrical system)
Abnormally worn injector

Improper injection timing
Clogged, seized injector
Suddenly became black w w Q Q Q
Color of exhaust gas is Gradually became black w Q Q
Questions

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Much fuel returns from the injector w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of
q q
code
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in
q
display of code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

14 WA200-6
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of pats in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Questions
Oil consumption suddenly increased w Q

Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA200-6 15
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy —
16 WA200-6
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.

Defective fuel supply pump oil seal
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective spray by injector
Improper injection timing

Questions
More than for other machines of same model Q Q Q Q

Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some
w
cylinders is low
Check items
Low idle speed is high Q

HST stall speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect fuel supply pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in display of code q
Much fuel returns from the injector q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” in display q
of code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

WA200-6 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Broken oil cooler core, O-ring
Broken hydraulic oil cooler or

Cracks inside cylinder block
Holes caused by pitting
power train oil cooler

Questions
Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q

shooting
Trouble-
Inspect cylinder block directly q q Check directly

Pressure-tightness test of oil cooler shows there is leakage q
Replace
Replace
Replace
Replace
Remedy —
18 WA200-6
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Improper selection of oil (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan

Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure Q w

Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Indicates pressure drop at low idle w
Indicates pressure drop at low, high idle Q w w w Q
Oil pressure monitor
Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy —
WA200-6 19
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in coolant”
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears,
w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
20 WA200-6
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too Causes
high
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature

Defective operation of thermostat
Drop in heat dissipation efficiency
Slipping fan belt, worn fan pulley

q
Clogged, crushed radiator fins

q Problem in coolant circulation system
Clogged, broken oil cooler

Rise in oil temperature in power train
Broken fan pulley bearing

q

o Carry out troubleshooting on applicable machine
Clogged radiator core

Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Rises quickly Q Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level Q w
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard are clogged with dirt or mud w w

Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant w
temperature

Inspect cylinder block directly q q
Inspect oil cooler directly q
Temperature difference between upper and lower tanks of radiator is large q
Troubleshooting
Check directly
When operation of thermostat is carried out, it does not open at cracking q

temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy —
WA200-6 21
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Abnormal combustion
Defective inside of muffler (dividing board out of position)

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
When exhaust manifold is touched immediately after starting engine, temperature of
Check items
some cylinders is low w Q

Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
22 WA200-6
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and chassis
Improper fuel injection timing (abnormality in coolant temperature

Abnormal combustion
Broken output shaft, parts in damper on applicable machine side

q
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for “S-15 Abnormal noise is made“, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
sensor, boost temperature sensor)

Improper gear train backlash
Worn camshaft bushing
Questions
Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
WA200-6 23
SEN03746-00
WA200-6 (KA SPEC.) Wheel loader

© 2007 KOMATSU
All Rights Reserved
24
SEN03786-00
WA200-6
WA200-6 70001 and up
50 Disassembly and assembly1

General information on disassembly
and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools ...............................................................................................................................11
WA200-6 1
SEN03786-00 50 Disassembly and assembly
How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The “Removal” section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know-how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q General tools that are necessary for removal
q Also the following information is described are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in the “Removal” section
tuted and should always be used are explained and listed below.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a: Know-how or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that there are instructions or
tools precautions for installing parts.
N: Tools newly developed for this 6 : This mark shows the amount of oil or coolant
model. They respectively have a to be drained.
new part number. 4 : Weight of part or component
R: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Installation
Blank: Tools already available for other
models. They can be used without q Except where otherwise instructed, installation
any modification. of parts is done in the r evers e order of
removal.
3) Circle mark Q in sketch column:
q Instructions and precautions for installing parts
q The sketch of the special tool is pre-
are shown with [*1] mark in the “Installation”
sented in the section of "Sketches of
section, identifying which step the instructions
special tools".
are intended for.
q This mark means part No. of special
q General tools that are necessary for installa-
* *** ****
tools starting with 79 T- -
and they can not be supplied from
tion are described as [1], [2]•••etc. and their
part names, part numbers and quantities are
Komatsu in Japan (i.e. locally made
not described.
parts).
q Marks shown in the “Installation” section stand
for the following.
k : Precautions related to safety in execution
of the work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating materials
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
2 WA200-6
2. Disassembly and assembly of assemblies Disassembly

q In “Disassembly” section, the work procedures,
Special tools precautions and know-how for carrying out
q Special tools which are deemed neces- those procedures, and quantity of the oil and
sary for disassembly or assembly of parts coolant drained are described.
are described as A1,•••X1 etc. and their q General tools that are necessary for disassem-
part names, part numbers and quantities bly are described as [1], [2]•••etc. and their part
are described in the special tool list. names, part numbers and quantities are not
q Also the following information is described described.
in the special tool list. q The meanings of the symbols used in “Disas-
1) Necessity sembly” section are as follows.
t : Special tools that cannot be substi- k : This mark indicates safety-related precau-
tuted and should always be used tions that must be followed when imple-
(installed). menting the work.
q : Special tools that will be useful if avail- a : Know-how or precautions for the work
able and are substitutable with com- 6: Quantity of oil or coolant drained
mercially available tools.
2) Distinction of new and existing special
tools
N : Tools newly developed for this Assembly
model. They respectively have a q In “Assembly” section, the work procedures,
new part number. precautions and know-how for carrying out
R : Tools with upgraded part numbers. those procedures, and quantity of the oil and
They are remodeled from already coolant added are described.
available tools for other models. q General tools that are necessary for assembly
Blank : Tools already available for other are described as [1], [2]•••etc. and their part
models. They can be used without names, part numbers and quantities are not
any modification. described.
3) Circle mark Q in sketch column: q The meanings of the symbols used in “Assem-
q The sketch of the special tool is pre- bly” section are as follows.
sented in the section of "Sketches of k : Precautions related to safety in execution
special tools". of the work
q This mark means part No. of special a : This mark gives guidance or precautions
* *** ****
tools starting with 79 T- -
and they can not be supplied from
when doing the procedure.
2 : Type of coating materials
Komatsu in Japan (i.e. locally made 3 : Tightening torque
parts). 5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
WA200-6 3
Coating materials list 1

(Rev. 2007.06)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 WA200-6
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not be applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
Grease
400 g Bellows-type resistance higher than molybdenum disulfide

Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
WA200-6 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Steel can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 WA200-6
Special tool list 1

a Tools with part number 79QT-QQQ-QQQQ can not be supplied (they are items to be locally manufac-
tured).
a Necessity : t ........ Cannot be substituted, should always be installed (used)
: q ........ Extremely useful if available or can be substituted with commercially avail-
able part
a New/remodel: : N......... Tools with new part numbers, newly developed for this model
: R......... Tools with upgraded part numbers, remodeled from items already avail-
able for other models
: Blank .. Tools already available for other models, can be used without any modifi-
cation
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
Installation of engine front oil

Engine front oil seal 1 795-799-6400 Seal puller t 1 seal
Engine rear oil seal 2 795-799-6500 Seal puller t 1 Installation of engine rear oil seal
3 795-799-6700 Puller t 1 Removal of fuel injector
Cylinder head assembly,
fuel injector assembly 4 795-799-1131 Gear t 1 Positioning of crankshaft
A
5 795-799-8150 Remover q 1 Removal of inlet connector
Cylinder head assembly, 6 790-331-1120 Wrench (Angle) q 1 Angle tightening of bolt
engine front oil seal Judgment of cylinder head bolt
assembly 7 795-790-4510 Gauge q 1 length
Cooling fan assembly 8 791-415-2002 Remover t 1 Removal of cooling fan
1 790-201-2840 Spacer t 1 Press fitting of output shaft
2 793T-417-1110 Push tool t 1 Q bearing
790-101-5201 Push tool kit t 1
790-101-5311 • Plate 1 Press fitting of oil seal of parking
3 brake case
790-101-5221 • Grip 1
01010-51225 • Bolt 1
793T-417-1120 Push tool t 1 Q
Press fitting of dust seal of park-
4 790-101-5221 Grip t 1 ing brake case
01010-81225 Bolt t 1
5 799-301-1500 Oil leak tester t 1 Operation test of transfer clutch
Removal and installation of
8 790-201-3260 Bolt (12 x 1.75 mm) q 2 parking brake assembly, cage
assembly and front case
Transfer assembly and D
parking brake assembly 9 790-102-2900 Puller q 1 Disassembly of HST motor 1
10 792-735-2420 Collar t 1 shaft and ring gear assembly
11 790-101-2501 Puller q 1 Removal of carrier assembly
Disassembly of HST motor 2
12 790-201-1320 Spacer t 1 gear and bearing assembly
13 790-101-3101 Bearing puller q 1 Disassembly of output shaft and
14 793T-417-1130 Push tool t 1 Q gear assembly
15 790-101-3501 Gear puller q 1 Removal of HST motor 1 gear

and outer race
Disassembly of HST motor 1
16 790-101-3401 Bearing puller q 1 gear and outer race
17 79G-17L-1000 Bar t 1 Removal of HST motor 1 gear

shaft and bearing
18 795-100-1291 Sleeve driver t 1 Removal of clutch housing
WA200-6 7
New/Remodel
Necessity
Sketch
Q'ty
HST motor 1, 2 gear and bear-

19 796-430-1110 Push tool t 1 ing assembly
20 790-470-1410 Collar t 1 Assembly of HST motor 1 gear

and outer race
Transfer assembly and 21 796-667-1310 Collar t 1 Installation of HST motor 1 gear
parking brake assembly D 22 791-126-0130 Push tool t 1 shaft and bearing
Commercially Measurement of output shaft
23 available Torque wrench q 1 and rotation torque
24 790-434-1470 Push tool t 1 Installation of parking brake and

plate
793T-623-1170 Push tool t 1 Q
793T-422-1230 Push tool t 1 Q Press fitting of axle shaft bear-
1
793T-423-1110 Push tool t 1 Q ing inner race
792T-446-1150 Push tool t 1 Q
793T-422-1240 Seal support t 2 Q
2 793T-423-1120 Seal support t 2 Q Axle shaft oil seal support
01016-50860 Bolt t 6
793T-659-1110 Push tool t 1 Q Press fitting of axle shaft bearing
3
790-201-2750 Spacer t 1 inner race
Adjustment of axle shaft bearing
4 793T-423-1150 Holder t 1 Q shim

790-101-5271 • Plate 1
Axle housing assembly 5 Removal of axle shaft
790-101-5221 • Grip 1
01010-51225 • Bolt 1
6 790-101-3101 Bearing puller q 1 Removal of axle shaft bearing
7 790-101-3501 Gear puller q 1
791T-465-1130 Push tool t 1 Q Removal of ring gear
8
790-201-2670 Plate t 1
H Installation of planetary carrier
9 799-501-1120 Pin t 1
roll pin
Removal and installation of pin-
10 790-445-5980 Guide bar t 1 ion gear shaft
11 Commercially Dial gauge q 1 Measurement of planetary car-

available rier end play
Measurement of housing start-
12 79A-264-0021 Push-pull scale q 1 ing torque
13 799-301-1500 Oil leak tester t 1 Operation check of clutch piston
Removal and installation of pin-
14 797-101-1211 Wrench t 1 ion shaft nut
15 793-615-1100 Wrench t 1 No-load operation torque of lim-

ited slip differential
16 793T-422-1220 Push tool t 1 Q Press fitting of pinion shaft bear-
17 797T-423-1320 Push tool t 1 Q ing
Differential assembly
Press fitting of pinion shaft cage
18 792T-413-1130 Push tool t 1 Q oil seal
19 793-520-2202 Installer q 3 Installation of brake piston and

check for brake oil leak
20 790-190-1500 Pump assembly t 1
21 799-101-5210 Nipple t 1 Check for brake oil leak
22 793T-422-1611 Plate t 1 Q
8 WA200-6
New/Remodel
Necessity
Sketch
Q'ty
23 791T-465-1210 Push tool t 1 Q Removal of shaft
24 790-201-3260 Bolt (12 x 1.75 mm) q 2 Removal and installation of

upper cover and bearing carrier
Removal of pinion gear assem-
25 791-615-2130 Sleeve t 1 bly
26 Commercially Puller q 1 Removal of carrier bearing

available
Removal of differential case
27 79G-05V-1400 Bar t 1 bearing outer race
28 792T-413-1120 Push tool t 1 Q Assembly of limited slip differen-

tial assembly
Differential assembly H Commercially
29 available Depth gauge q 1 Selection of plate thickness
30 Commercially Torque wrench q 1 Measurement of no-load opera-

available tion torque of sun gear shaft
31 Commercially Dial gauge q 1 Measurement of backlash of

available bevel gear
Installation of long cage shaft
32 790-201-2830 Spacer t 1 bearing
33 791-126-0211 Adapter t 1 Installation of long cage shaft

assembly
Commercially
34 available Depth micrometer q 1 Adjustment of trunnion cap shim
1 791-830-1410 Push tool t 1 Press fitting of bearing to front

frame and upper hinge
Press fitting of bearing to front
Center hinge pin J 2 791-630-1260 Push tool t 1 frame and lower hinge
Commercially Measurement of clearance

3 available Thickness gauge q 1 between front frame and
retainer
1 790-201-2720 Push tool q 1
790-201-2150 Push tool t 1
2
790-201-2830 Push tool t 1
Piston pump and motor 3 790-201-2740 Push tool q 1 Disassembly and assembly of
assembly S piston pump and motor
4 02010-20783 Bolt q 1
790-201-2740 Push tool t 1
5 793T-417-1120 Push tool q 1
02010-20783 Bolt q 1
790-502-1003 Repair stand t 1 Disassembly and assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
2 790-102-3802 Wrench assembly t 1 cylinder head
790-102-1320 Socket (Lift) t 1
790-102-1330
or Socket (Bucket) Removal and installation of
Hydraulic cylinder 3 Commercially (Width across flats: t 1 piston nut
assembly U available 46 mm)
790-302-1280 Socket (Steering) t 1

790-101-5021 • Grip 1
4 01010-50816 • Bolt 1 Press fitting of cylinder head
bushing
790-201-1791 • Push tool (Lift, bucket) 1
790-201-1811 • Push tool (Steering) 1
WA200-6 9
New/Remodel
Necessity
Sketch
Q'ty

790-101-5021 • Grip 1
5 01010-50816 • Bolt 1 Installation of dust seal
790-201-1610 • Plate (Lift, bucket) 1
Hydraulic cylinder 790-201-1550 • Plate (Steering) 1
assembly U
6 790-720-1000 Expander q 1
796-720-1670 Ring (Lift, bucket) q 1
07281-01159 Clamp (Lift, bucket) q 1 Installation of piston ring
7
796-720-1740 Ring (Steering) q 1
07281-00809 Clamp (Steering) q 1
1 793-498-1120 Clear plate t 2
Adjustment of clearance of
1 2 793-498-1130 Plate t 2 window glass
Operator's cab glass
(stuck glass) X 3 793-498-1110 Magnet t 2
2 793-498-1210 Lifter (Suction cup) t 2 window glass
10 WA200-6
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 Push tool
9JF00891
D4 Push tool
9JF00892
WA200-6 11
D14 Push tool
COW16161
H1 Push tool
9JF00902
12 WA200-6
H1 Push tool
9JF00893
H1 Push tool
9JF00894
WA200-6 13
H1 Push tool
H2 Seal support
9JF00896
14 WA200-6
H2 Seal support
9JF00895
H3 Push tool
9JF00899
WA200-6 15
H4 Holder
9JF00897
H8 Push tool
COW16159
16 WA200-6
H16 Push tool
9JF00898
H17 Push tool
WA200-6 17
H18 Push tool
9JF00901
H22 Plate
18 WA200-6
H23 Push tool
H28 Push tool
WA200-6 19
SEN03786-00

© 2007 KOMATSU
All Rights Reserved
20
SEN03787-00
WA200-6
WA200-6 70001 and up

Engine and cooling system
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 5
Removal and installation of cylinder head assembly .................................................................................... 12
Removal and installation of engine hood assembly ...................................................................................... 25
Removal and installation of radiator.............................................................................................................. 29
Removal and installation of air aftercooler .................................................................................................... 32
Removal and installation of hydraulic oil cooler assembly ............................................................................ 34
Removal and installation of engine assembly ............................................................................................... 36
Removal and installation of engine front oil seal assembly .......................................................................... 43
Removal and installation of engine rear oil seal assembly ........................................................................... 46
Removal and installation of cooling fan and fan motor assembly ................................................................. 49
Removal and installation of fuel tank assembly ............................................................................................ 52
WA200-6 1
Removal and installation of fuel

supply pump assembly 1
Removal
install the lock bar to the frame to fix the
front and rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Open and fix right engine side cover (1).

a Check that the cover is locked securely. 3. Disconnect fuel return hoses (6) and (7) from
fuel supply pump (4).
4. Disconnect wiring harness connector CN-CP3

(8) from fuel supply pump (4).
5. Disconnect fuel supply hose (9) from fuel sup-

ply pump (4). [*1]
2. Disconnect fuel hoses (2) and (3) from fuel

supply pump (4).
a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
area.
a Press lock (L) from both sides and pull out
hose (a).
a Plug the disconnected hoses to prevent 6. Remove fuel high-pressure pipe clamps (10)
fuel leakage. and (11).
2 WA200-6
7. Remove boot (12) and fuel high-pressure pipe Installation

(13) from fuel supply pump (4). [*2] q Carry out installation in the reverse order to
a Remove the boot on the common rail side removal.
of high-pressure pipe (13) and loosen the a The internal parts of the fuel hose adapter
sleeve nut. may be damaged when it is removed.
Accordingly, do not reuse the fuel hose but
use new one when assembling again as a
rule.
[*1]
3 Joint bolt: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*2]
q How to install high-pressure pipe (13)
1. Tighten the sleeve nut with the fingers.
2. Check that the high-pressure pipe is installed

correctly and tighten the sleeve nut to the fol-
8. Remove 3 mounting nuts at part (A) and fuel lowing torque.
supply pump assembly (14). [*3] 3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
k Be sure to use the genuine fuel high-
p r e s s u r e p ip e c l a m p a n d s t r i c t l y
o b s e r v e t h e s p e c i f i e d t i g h t e ni n g
torque.
3. Install boot (12).

a Direct the slit of the boot down.
a The boot is installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
[*3]
a If too much grease is applied to O-ring (16), it
a Remove fuel supply pump assembly (13) will ooze out. Accordingly, do not apply grease
and the gear together. The gear does not so much. (Apply grease to the O-ring groove
have a positioning mark (missing tooth), area of part (B).)
etc. a When installing new fuel supply pump mount-
ing stud bolts (17) to replace the existing ones,
apply LOCTITE (LT-2) to them.
Install fuel supply pump (15).
3 Fuel supply pump mounting nut:

24 ± 4 Nm {2.45 ± 0.41 kgm}
WA200-6 3
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
circuit".
4 WA200-6
Removal and installation of fuel 4. Lift off muffler (2).

injector assembly 1 a Take care that the muffler will not interfere
with water drain tube (3).
4
Special tools Muffler assembly: Approx. 25 kg
New/Remodel
Necessity
Sketch
Q'ty
3 795-799-6700 Puller t 1
A 4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k Lower the work equipment to the ground, 5. Using hexagonal wrench (width across flats:
stop the engine, apply the parking brake, 3 mm), remove blow-by duct (4). [*1]
k Disconnect the cable from the negative (–) 6. Remove 4 mounting nuts (5) and cylinder head
terminal of the battery. cover (6). [*2]
k If the radiator coolant temperature is high,
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and
then drain the coolant.
1. Loosen the radiator cap to drain the coolant.

6 Radiator: Approx. 17 l
2. Remove the engine hood assembly. For

details, see "Removal and installation of
engine hood assembly".
3. Remove muffler cover (1).

7. Disconnect wiring harness connector (7).
a While pressing up the lock of wiring har-
ness connector (7) with flat-head screw-
d r iv er [1 ], p ul l t he co nne cto r in th e
direction of the arrow.
a Do not remove fuel pressure sensor (PS)
if it does not need to be replaced.
8. Disconnect wiring harness connectors CN-

INJ1 (8) and CN-INJ2 (8a). [*3]
a While pressing the lock of the wiring har-
ness connector with flat-head screwdriver
[2], pull the connector.
a Move wiring harness (9) toward the intake
manifold.
WA200-6 5
11. Position the crankshaft according to the follow-

ing procedure.
1) Remove plate (12) of the frame on the
starting motor side.
2) Loosen and move the relay and wiring
harness (13) at the bottom of the starting
motor.
3) Remove plug (14) under the starting motor
and set tool A4.
4) Rotate the crankshaft forward (counter-
clockwise seeing from the flywheel side)
to set marks (M1) and (M2).
Mark (M1):Top of projection of front cover
Mark (M2):A wide slit on slitted revolution
sensor disc at rear of crank-
shaft pulley
a Set the projection top of mark (M1)
within the wide slit (M2).
a When the marks are set as above,
the piston of the No. 1 or No. 4 cylin-
der is 76 – 88° before the top dead
center.
a See Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the crankshaft.
9. Remove 4 boots (10). [*4]
10. Remove 4 high-pressure pipes (11). [*5]

a Remove the boots of the fuel high-pres-
sure pipes on the common rail side and
loosen the sleeve nuts.
6 WA200-6
13. Remove 8 crossheads (18).

a Record the positions and shapes of holes
(a) and (b) of each crosshead. (Reinstall
each crosshead in the same direction.)
12. Remove the 8 mounting bolts and rocker arm

(15).
a Loosen locknut (16), and then loosen
adjustment screw (17) by 2 – 3 turns so
that an excessive force will not be applied 14. Remove retaining nuts (19) and 4 inlet connec-
to the push rod when the rocker arm is tors (20).
installed. a Before removing, clean the inlet connec-
tors carefully so that mud, etc. sticking
around them will not enter their holes.
a Tool A5 is set for removal of inlet connec-
tor (20). (See the special tools list.)
WA200-6 7
15. Remove 2 wiring harness mounting nuts (22) Installation

from fuel injector assembly (21). a The internal parts of the fuel hose adapter may
be damaged when it is removed. Accordingly,
Wiring harness
Cylinder No. do not reuse the fuel hose but use new one
color
when assembling again, as a rule.
White 1, 3 When replacing the fuel injector assembly with
Black 2, 4 new one, be sure to replace the inlet connector
with new one, too.
16. Remove 2 mounting bolts (23) of fuel injector 1. Fuel injector assembly
assembly (21). a Check that the fuel injector sleeve (24) is
free from flaw and dirt.
17. Using tool A3, remove fuel injector assembly

(21). 1) Fit O-ring (25) and gasket (26) to fuel
a Take care that dirt and foreign matter will injector (21).
not enter the fuel injector assembly 2) Apply engine oil to O-ring (25) of fuel
mounting area. injector (21) and the mounting hole on the
cylinder head side.
2 O-ring (25) and mounting hole on
the cylinder head side: Engine oil
(For details, see “Table of fuel,
coolant and lubricants”)
3) While setting convex and concave parts
(A), install holder (27) to fuel injector (21).
8 WA200-6
4) Insert fuel injector (21) in the cylinder 11) Tighten retaining nut (19).
head, directing its fuel inlet hole toward 3 Retaining nut (19):
the air intake manifold. 50 ± 5 Nm {5.1 ± 0.5 kgm}
5) Tighten 2 mounting bolts (23) of fuel injec-
tor (21) by 3 – 4 turns.
12) Install the wiring harnesses to fuel injector

(21) and tighten 2 mounting nuts (22).
6) Apply engine oil to the mounting hole of 3 Wiring harness mounting nut (22):
inlet connector (20) on the cylinder head 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
side. a Installed positions of wiring har-
2 Mounting hole of inlet connector: nesses
Engine oil
Wiring harness
(For details, see “Table of fuel, Cylinder No.
color
7) Apply engine oil to O-ring (28) of inlet con- White 1, 3
nector (20). Black 2, 4
2 O-ring (28): Engine oil
(For details, see “Table of fuel,
8) Insert inlet connector (20) perfectly, while
setting part (B) to the groove on the cylin-
der head side.
9) Secure inlet connector (20) by tightening

retaining nut (19) lightly.
3 Retaining nut (19):
15 ± 5 Nm {1.5 ± 0.5 kgm}
tor (21) alternately.
3 Fuel injector mounting bolt (23):
8.0 ± 0.8 Nm {0.8 ± 0.08 kgm}
WA200-6 9
q Precautions for installing inlet connector 2. Crosshead and rocker arm assembly
1) When replacing the fuel injector assembly 1) Install the crosshead and rocker arm.
with new one, be sure to replace inlet con- a The shapes of holes (a) and (b) of
nector, too. each crosshead are different. Accord-
2) Check the inlet connector visually. If it has ingly, when reusing the crossheads,
any of the following faults, replace it. install each of them to the same
1] There is a burr or a worn part at front intake/exhaust valve in the same
end (a) or rear end (b) of the inlet direction as it was installed.
connector. 2) Check that the ball of adjustment screw
2] There is foreign matter in the edge fil- (17) is set in the push rod socket securely
ter at rear end (c) of the inlet connec- and then tighten mounting bolts (29).
tor. 3 Rocker arm mounting bolt (29):
3] The O-ring at upper part (d) of the 36 ± 5 Nm {3.7 ± 0.5 kgm}
inlet connector is cracked or deterio- 3) Adjust the valve clearance. For details,
rated. see Testing and adjusting, "Adjusting
valve clearance".
3 Locknut (16):
24 ± 4 Nm {2.4 ± 0.4 kgm}
3) Check the inlet connector visually. If it has

any of the following faults, replace it and
fuel injector assembly together.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face has fine streaks or
cracks.
10 WA200-6
q Carry out the following installation in the 2) Tighten fuel high-pressure pipes (30) –
reverse order to removal. (33) in the following order.
1] Tighten the cylinder head side of fuel
[*1] high-pressure pipes (30) and (33).
3 Blow-by duct mounting bolt: 2] Tighten the common rail side of fuel
7 ± 2 Nm {0.7 ± 0.2 kgm} high-pressure pipes (30) and (33).
[*2] high-pressure pipes (31) and (32).
3 Cylinder head cover mounting nut (5): 4] Tighten the common rail side of fuel
24 ± 4 Nm {2.4 ± 0.4 kgm} high-pressure pipes (31) and (32).
3 Sleeve nut:
[*3] 35 ± 3.5 Nm {3.6 ± 0.4 kgm}
k Install each fuel high-pressure pipe and 3) Install 4 boots (10) to the fuel high-pres-
wiring harness at least 10 mm apart from sure pipes.
each other. a Direct the slit of the boot out and
down.
[*4], [*5] a The boots are installed so that fuel
k Do not bend the fuel high-pressure pipe to will not spout over the hot parts of the
correct before installing. engine to catch fire when it leaks for
k Be sure to use the genuine fuel high-pres- some reason.
sure pipe clamps and observe the tighten-
ing torque.
a If the taper seal area of the fuel high-pressure
pipe has any of the following defects, replace
the fuel high-pressure pipe.
q There is visible lengthwise slit (b) or spot (c) in
range (a) of 2 mm from the end.
q Taper seal end (d) at 2 mm from the end has
stepped-type wear which your nail can feel.
q Bleeding air
circuit".
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
1) Temporarily install fuel high-pressure coolant level again.
5
pipes (30) – (33).
Total amount of coolant: Approx. 17 l
3 Sleeve nut:
(For details, see "Table of fuel, coolant
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
and lubricants")
WA200-6 11
Removal and installation of 4. Lift off muffler (2).

cylinder head assembly 1 a Take care that the muffler will not interfere
with water drain tube (3).
4
Special tools Muffler assembly: Approx. 25 kg
New/Remodel
Necessity
Sketch
Q'ty
3 795-799-6700 Puller t 1
4 795-799-1131 Gear t 1
A 5 795-799-8150 Remover q 1
6 790-331-1120 Wrench (angle) q 1
7 795-790-4510 Gauge q 1
Removal
the lock bar to the frame to fix the front and 5. Disconnect engine intake air heater wiring har-
rear frames. ness terminal CN-E07B (4). [*1]

2. Remove the engine hood assembly. For 6. Disconnect wiring harness connector (5).
engine hood assembly". 7. Remove the belt and air conditioner compres-
sor assembly (6). [*2]
3. Remove muffler cover (1). a Fix air conditioner compressor assembly
(6) to the machine with ropes.
12 WA200-6
8. Remove 2 bracket mounting bolts (7). 13. Disconnect wiring harness connector (14).
a Remove bracket (8) and air tube and hose a While pressing up the lock of wiring har-
assembly (9) together. ness connector (14) with flat-head screw-
d r iv er [1 ], p ul l t he co nne cto r in th e
direction of the arrow.
a Do not remove fuel pressure sensor (PS)
if it does not need to be replaced.
14. Disconnect wiring harness connectors CN-

INJ1 (15) and CN-INJ2 (16). [*4]
a While pressing the lock of the wiring har-
ness connector with flat-head screwdriver
[2], pull the connector.
a Move wiring harness (17) toward the
intake manifold.
9. Remove hose clamp (10) and tube clamp (11).

[*3]
10. Disconnect air tube and hose assembly (9)

between the air aftercooler and intake mani-
fold.
11. Remove water drain tube (12).
12. Remove 2 wiring harness clamps (13).
WA200-6 13
15. Remove muffler mounting bracket (18). 19. Remove wiring harness clamp (24).
20. Move wiring harness (25) down.
21. Disconnect fuel return hose (26) of the cylinder

head. [*5]
22. Disconnect fuel return hose (27) of the com-

mon rail. [*6]
23. Remove boot (28). [*7]
24. Disconnect high-pressure pipe (29). [*8]

a Remove the boot of the fuel high-pressure
pipe on the fuel supply pump side and
16. Disconnect fuel filter hoses (19) and (20). loosen the sleeve nut.
a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
area.
a Press lock (L) from both sides and pull out
hoses (19) and (20).
a Plug the disconnected hoses to prevent
fuel leakage.
17. Remove fuel filter and bracket assembly (21).
25. Remove 4 boots (30). [*9]
26. Remove 4 high-pressure pipes (31). [*10]

a Remove the boots of the fuel high-pres-
sure pipes on the common rail side and
loosen the sleeve nuts.
18. Remove fuel high-pressure pipe clamps (22)

and (23).
14 WA200-6
27. Remove the mounting bolts of bracket (32). 34. Put wrench [1] in part (A) (width across flats:
12.7 mm) of tensioner assembly (40) and turn
28. Remove hose clamps (33) and (34). [*11] it in the unwinding direction to decrease the
tension of belt (41).
29. Disconnect air tube and hose assembly (35) k Set wrench [1] securely to part (A) of
between the air aftercooler and turbocharger. tensioner assembly (40) before turning
a Remove bracket (32) and air tube and it. (The spring of tensioner assembly
hose assembly (35) together. (40) is strong. If wrench [1] is set
incompletely and turned, it comes off
30. Disconnect radiator upper hose (36). [*12] and that is very dangerous.)
k After removing belt (41), return ten-
31. Remove cover (37). sioner assembly (40) slowly and care-
fully.
k Take care not to catch your finger
between the pulley and belt (41) during
work.
32. Remove 3 heat insulation plates (38).
33. Remove alternator belt cover (39).
WA200-6 15
35. Disconnect wiring harness connectors CN-E02 39. Remove the mounting bolts of exhaust mani-
(38) and CN-E03 (29). fold (44), leaving some of them installed. [*14]
36. Remove alternator assembly (40). 40. Sling exhaust manifold and turbocharger
assembly (45) and remove the remaining
mounting bolts.
41. Lift off exhaust manifold and turbocharger

assembly (45).
a Pull out exhaust manifold and turbo-
charger assembly (45) from elbow 46 and
lift it off.
4 Exhaust manifold and turbocharger
assembly: 15 kg
37. Remove engine slinger (41).
42. Remove elbow (46).
38. Disconnect turbocharger lubricating oil inlet

tube (42) and drain hose (43). [*13]
a If turbocharger lubricating oil inlet tube
(42) cannot be easily disconnected from
the turbocharger, disconnect it from the oil
filter head.
a If the tool cannot be put in the flange
mounting bolt, disconnect drain hose (43)
from the cylinder block.
16 WA200-6
43. Remove water tube (47). [*15] a When the marks are set as above,
the piston of the No. 1 or No. 4 cylin-
44. Remove pulley mounting bracket (48). [*16] der is 76 – 88° before the top dead
center.
a See Testing and adjusting, "Adjusting
valve clearance".
a Use tool A4 to rotate the crankshaft.
45. Using hexagonal wrench (width across flats: 3

mm), remove blow-by duct (49). [*17]
46. Disconnect heater hose (50).
47. Remove 4 mounting nuts (51) and cylinder

head cover (52). [*18]
48. Position the crankshaft according to the follow-

ing procedure.
1) Remove plate (53) of the frame on the
starting motor side.
2) Loosen and move the relay and wiring
harness (54) at the bottom of the starting
motor.
3) Remove plug (55) under the starting motor
and set tool A4.
4) Rotate the crankshaft forward (counter-
clockwise seeing from the flywheel side)
to set marks (M1) and (M2).
Mark (M1): Top of projection of front cover
Mark (M2): A wide slit on slitted revolution
sensor disc at rear of crank-
shaft pulley
a Set the projection top of mark (M1)
within the wide slit (M2).
WA200-6 17
49. Remove the 8 mounting bolts and rocker arm 51. Remove retaining nuts (60) and 6 inlet connec-
(56). tors (61).
a Loosen locknut (57), and then loosen a Before removing, clean the inlet connec-
adjustment screw (58) by 2 – 3 turns so tors carefully so that mud, etc. sticking
that an excessive force will not be applied around them will not enter their holes.
to the push rod when the rocker arm is a Tool A5 is set for removal of inlet connec-
installed. tor (61). (See the special tools list.)
50. Remove 8 crossheads (59). 52. Remove 2 wiring harness mounting nuts (63)
a Record the positions and shapes of holes from fuel injector assembly (62).
(a) and (b) of each crosshead. (Reinstall
Wiring harness
each crosshead in the same direction.) Cylinder No.
color
White 1, 3
Black 2, 4
53. Remove 2 mounting bolts (64) of fuel injector

assembly (62).
18 WA200-6
54. Using tool A3, remove fuel injector assembly Installation

(62). a The internal parts of the fuel hose adapter may
a Take care that dirt and foreign matter will be damaged when it is removed. Accordingly,
not enter the fuel injector assembly do not reuse the fuel hose but use new one
mounting area. when assembling again, as a rule.
When replacing the fuel injector assembly with
new one, be sure to replace the inlet connector
with new one, too.
1. Cylinder head assembly

1) Using tool A7, measure stem length (a) of
each cylinder head mounting bolt and
check that it is shorter than using limit (b).
(See the special tools list.)
q Using limit length of bolt (b): 132.1
mm or less
a If a bolt is longer than the using limit,
replace it.
55. Remove push rods (65).
56. Remove 5 mounting bolts (66) and rocker

housing (67).
2) Set cylinder head gasket (70).

a Check that there is no dirt and foreign
matter on the cylinder head mounting
surface and in the cylinders.
a Check that the holes of the cylinder
57. Remove 18 mounting bolts (68) and lift off cyl- head gasket are matched to the holes
inder head assembly (69). of the cylinder head.
3) Set cylinder head (69) on the cylinder
4 Cylinder head assembly: 50 kg block.
4) Tighten 18 mounting bolts (68) 2 – 3 turns
58. Remove cylinder head gasket (70). with the fingers, and then tighten them
according to the following procedure.
2 Threaded part and seat of mount-
ing bolt: Engine oil (For details,
see "Table of fuel, coolant and
lubricants")
WA200-6 19
q When not using angle tightening tool

4] After steps 1] and 2], make marks on the
cylinder head and each bolt with a marker.
5] Tighten the bolt by 90 ± 5°.
q Tightening procedure for mounting bolts

(68).
1] 90 ± 3 Nm {9.2 ± 0.3 kgm}
2] Check the tightening torque of 90 ± 3 Nm
{9.2 ± 0.3 kgm}. 2. Fuel injector assembly
3] 90 ± 5° (Use the angle tightening tool) a Check that the fuel injector sleeve (62a) is
a Tighten the mounting bolts in the following free from flaw and dirt.
order.
a Tool A6 is set for angle tightening. (See
the special tools list.)
1) Fit O-ring (71) and gasket (72) to fuel

injector (62).
2) Apply engine oil to O-ring (71) of fuel
injector (62) and the mounting hole on the
cylinder head side.
2 O-ring (71) and mounting hole on
the cylinder head: Engine oil (For
details, see “Table of fuel, coolant
and lubricants”)
3) While setting convex and concave parts
(A), install holder (73) to fuel injector (62).
20 WA200-6
4) Install rocker housing (67). 8) Apply engine oil to the mounting hole of inlet
3 Rocker housing mounting bolt (66): connector (61) on the cylinder head side.
24 ± 4 Nm {2.4 ± 0.4 kgm} 2 Mounting hole of inlet connector:
5) Install push rods (65). Engine oil (For details, see "Table
of fuel, coolant and lubricants")
9) Apply engine oil to O-ring (74) of inlet con-
nector (61).
2 O-ring (74): Engine oil (For details,
see "Table of fuel, coolant and
lubricants")
10) Insert inlet connector (61) perfectly, while
setting part (B) to the groove on the cylin-
der head side.
6) Insert fuel injector (62) in the cylinder

head, directing its fuel inlet hole toward
the air intake manifold.
tor (62) by 3 – 4 turns.
11) Secure inlet connector (61) by tightening

retaining nut (60) lightly.
15 ± 5 Nm {1.5 ± 0.5 kgm}
tor (62) alternately.
3 Fuel injector mounting bolt (64):
8.0 ± 0.8 Nm {0.8 ± 0.08 kgm}
13) Tighten retaining nut (60).
50 ± 5 Nm {5.1 ± 0.5 kgm}
WA200-6 21
14) Install the wiring harnesses to fuel injector q Precautions for installing inlet connector
(62) and tighten 2 mounting nuts (63). 1) When replacing the fuel injector assembly
3 Wiring harness mounting nut (63): with new one, be sure to replace inlet con-
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} nector, too.
a Installed positions of wiring har- 2) Check the inlet connector visually. If it has
nesses any of the following faults, replace it.
1] There is a burr or a worn part at front
Wiring harness
Cylinder No. end (a) or rear end (b) of the inlet
color
connector.
White 1, 3 2] There is foreign matter in the edge fil-
Black 2, 4 ter at rear end (c) of the inlet connec-
tor.
3] The O-ring at upper part (d) of the
inlet connector is cracked or deterio-
rated.
3) Check the inlet connector visually. If it has

any of the following faults, replace it and
fuel injector assembly together.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face will have fine streaks or
cracks.
22 WA200-6
3. Crosshead and rocker arm assembly q Carry out the following installation in the
1) Install the crosshead and rocker arm. reverse order to removal.
a The shapes of holes (a) and (b) of
each crosshead are different. Accord- [*1]
ingly, when reusing the crossheads, 3 Wiring harness terminal CN-E07B (4):
install each of them to the same 4.0 ± 0.6 Nm {0.41 ± 0.06 kgm}
intake/exhaust valve in the same
direction as it has been installed. [*2]
2) Check that the ball of adjustment screw Adjust the air conditioner compressor belt tension.
(58) is set in the push rod socket securely For details, see "Adjusting air conditioner compres-
and then tighten mounting bolts (75). sor belt tension" in Testing and adjusting.
3 Rocker arm mounting bolt (75):
36 ± 5 Nm {3.7 ± 0.5 kgm} [*3]
3) Adjust the valve clearance. For details, 3 Hose clamp (10):
see Testing and adjusting, "Adjusting 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
valve clearance". 3 Tube clamp (11): 10 ± 2 Nm {1.0 ± 0.2 kgm}
3 Locknut (57):
24 ± 4 Nm {2.4 ± 0.4 kgm} [*4]
k Install each fuel high-pressure pipe and
wiring harness at least 10 mm apart from
each other.
[*5], [*6], [*7], [*8], [*9], [*10]

k Do not bend the fuel high-pressure pipe to
correct before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
a If the taper seal area of the fuel high-pressure
pipe has any of the following defects, replace
the fuel high-pressure pipe.
q There is visible lengthwise slit (b) or spot (c) in
range (a) of 2 mm from the end.
q Taper seal end (d) at 2 mm from the end has
stepped-type wear which your nail can feel.
1) Temporarily install fuel high-pressure

pipes (76) – (79).
3 Sleeve nut:
0.2 – 0.8 Nm {0.02 – 0.08 kgm}
2) Tighten fuel high-pressure pipes (76) –
(79) in the following order.
high-pressure pipes (76) and (79).
WA200-6 23
2] Tighten the common rail side of fuel [*14]

high-pressure pipes (76) and (79). q Tighten the exhaust manifold mounting bolts
3] Tighten the cylinder head side of fuel according to the following procedure.
high-pressure pipes (77) and (78). 3 Exhaust manifold mounting bolts
4] Tighten the common rail side of fuel 1st time: Tighten [1] – [12] to 24 ± 4 Nm {2.4
high-pressure pipes (77) and (78). ± 0.4 kgm} in order.
5] Tighten the pump side of high-pres- 2nd time:Tighten [1] – [12] to 53 ± 6 Nm {5.4
sure pipe (29) and then tighten the ± 0.6 kgm} in order.
common rail side. 3rd time: Tighten only [1] – [4] to 53 ± 6 Nm
3 Sleeve nut: {5.4 ± 0.6 kgm} in order.
35 ± 3.5 Nm {3.6 ± 0.4 kgm}
3) Install 4 boots (30) to the fuel high-pres-
sure pipes.
a Direct the slit of the boot out and
down.
a The boots are installed so that fuel
will not spout over the hot parts of the
engine to catch fire when it leaks for
some reason.
4) Install fuel drain hose (26).
3 Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
[*15]
3 Water tube mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*16]
3 Bracket mounting bolt for pulley mount:
32 ± 5 Nm {3.3 ± 0.5 kgm}
[*17]
3 Blow-by duct mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
[*11] [*18]
3 Hose clamp (33): 3 Cylinder head cover mounting nut (48):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 24 ± 4 Nm {2.4 ± 0.4 kgm}
3 Hose clamp (34):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
q Bleeding air
[*12] Bleed air from the fuel system. For details, see
2 Radiator upper hose insertion area: Testing and adjusting, "Bleeding air from fuel
Gasket sealant circuit".
(THREEBOND 1206E or equivalent)
3 Radiator upper hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} q Refilling with coolant
[*13] specified level. Run the engine to circulate the
3 Mounting bolt of turbocharger lubricating oil coolant through the system. Then, check the
inlet tube (42): 35 ± 5 Nm {3.5 ± 0.5 kgm} coolant level again.
3
5
Mounting bolt of turbocharger lubricating oil
outlet hose (43): 10 ± 2 Nm {1.0 ± 0.2 kgm}
and lubricants")
24 WA200-6
Removal and installation of 5. Remove 4 wiring harness clamps (6) under the
engine hood assembly 1 left of the cab floor.
Removal 6. Disconnect washer motor wiring harness con-

k Stop the machine on a level ground and nector (7).
1. Open and fix right and left engine side covers

(1).
a Check that the covers are locked securely.
2. Open radiator grille (2).
7. Disconnect 2 washer hoses (8) from the left

side of the engine compartment.
3. Remove right and left fenders (3).
4. Remove right and left covers (4) and (5).

8. Remove right and left plates (9) and (10).
WA200-6 25
9. Open and fix cooling fan motor assembly (11).

a Check that cooling fan motor assembly is
locked securely.
14. Remove 2 heat insulation sheet fixing plates

(17).
10. Remove 4 mounting bolts (12) and cover (13). 15. Disconnect rear combination lamp connector
CN-BR1 (18).
11. Remove left stay mounting bolt (14).

16. Remove hose (19) between the air cleaner and
12. Remove right stay mounting bolt (15). turbocharger. [*1]
13. Remove right stay (16).

a The right stay must be removed since it
interferes with the engine hood when the
latter is removed.
26 WA200-6
17. Remove 3 air conditioner hose clamps (20) at 22. Remove exhaust pipe (26).
the bottom of the air cleaner.
23. Remove 4 fuel tank breather hose clamps (27).

18. Disconnect water separator wiring harness
connector CN-E42 (21) at the bottom of the 24. Remove clip (28) and disconnect hose (30)
fuel prefilter. from fuel tank breather (29).
19. Remove hose clamp (22) and disconnect fuel 25. Remove 2 front mounting bolts (31) on each of
hose (23). the right and left sides.
20. Disconnect fuel hose (24).
21. Remove fuel prefilter and bracket assembly

(25).
a Fix fuel prefilter and bracket assembly
WA200-6 27
26. Remove 1 rear mounting bolt (32) on each of Installation

the right and left sides. q Carry out installation in the reverse order to
removal.
[*1]
3 Hose clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
27. Lift off engine hood assembly (33).

4 Engine hood assembly: 230 kg
28 WA200-6
Removal and installation of 5. Remove air conditioner hose clamp (6).

radiator 1
6. Remove 2 hydraulic oil cooler hose clamps (7).
Removal
k Stop the machine on a level ground and set 7. Remove 3 wiring harness clamps (8).
rear frames. 8. Remove heat insulation rubber fixing plate (9).
stop the engine, apply the parking brake, 9. Remove heat insulation plate (10).


(1).
a Check that the covers are locked securely. 10. Remove 3 air conditioner hose clamps (11).
3. Open radiator grille (2). 11. Remove air conditioner receiver tank and
bracket assembly (12). [*1]
12. Remove 4 mounting bolts (13) and air condi-

tioner condenser (14).
a Fix air conditioner condenser (14) and air
conditioner receiver.
4. Remove right and left stays (3), (4) and (5).
WA200-6 29
13. Remove 4 mounting bolts (15) and bracket 17. Remove 4 mounting bolts (20) and plate (21).
(16).
18. Remove 2 upper radiator mounting bolts (22).

14. Disconnect radiator upper hose (17). [*2]
15. Disconnect radiator lower hose (18). [*3]
19. Disconnect overflow hose (23).
16. Open and fix cooling fan and fan motor assem-
bly (19).
a Check that cooling fan motor assembly is
locked securely.
30 WA200-6
20. Remove radiator (24) from the left side. [*4] [*4]
a When removing the radiator, take care not a Fit grommet (25) to the mounting hole.
to damage it. a Check that projection (A) of the radiator is fit-
ted to grommet.
a When installing the radiator, set drain hose
(26) in mounting hole (B) securely.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Air conditioner receiver tank mounting U-
clamp: 10.8 – 26.0 Nm {1.1 – 2.7 kgm}
[*2]
2 Radiator upper hose insertion area:
Gasket sealant
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
2 Radiator lower hose insertion area:
Gasket sealant q Refilling with coolant
(THREEBOND 1206E or equivalent) Add coolant through the coolant filler to the
3 Radiator lower hose clamp: specified level. Run the engine to circulate the
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} coolant through the system. Then, check the
coolant level again.
5 Total amount of coolant: Approx. 17 l
and lubricants")
WA200-6 31
Removal and installation of air 5. Remove upper 2 air aftercooler mounting bolts
aftercooler 1 (3).
Removal
6. Remove air aftercooler (4) from the left side.
1. Loosen the radiator cap to drain the coolant. [*3]
6
a When removing the air aftercooler, take
Radiator: Approx. 17 l
care not to damage it.
2. Remove the radiator. For details, see

"Removal and installation of radiator".
3. Disconnect air aftercooler upper hose (1). [*1]
4. Disconnect air aftercooler lower hose (2). [*2]
32 WA200-6
Installation
removal.
[*1]
3 Air aftercooler upper hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Air aftercooler lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
a Fit grommet (5) to the mounting hole.
a Check that projection (A) of the air aftercooler
is fitted to grommet (5).

and lubricants")
WA200-6 33
Removal and installation of 5. Remove upper 2 hydraulic oil cooler mounting

hydraulic oil cooler assembly 1 bolts (3).
Removal
rear frames.
6. Remove lower 2 hydraulic oil cooler mounting
1. Loosen the radiator cap to drain the coolant. bolts (4).
2. Remove the radiator. For details, see

"Removal and installation of radiator".
3. Disconnect hydraulic oil cooler upper hose (1).
4. Disconnect hydraulic oil cooler lower hose (2).

a Plug the disconnected hose to prevent oil
leakage.
7. Remove 2 hydraulic oil cooler mounting bolts

(5) on the right side.
34 WA200-6
8. Remove hydraulic oil cooler assembly (6) from Installation

the right side. q Carry out installation in the reverse order to
a When removing the hydraulic oil cooler removal.
assembly, take care not to damage it.
q Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see "Table of
fuel, coolant and lubricants"): Only nec-
essary quantity

and lubricants")
WA200-6 35
Removal and installation of 4. Remove stay (2).

engine assembly 1
5. Remove air conditioner hose clamp (3).
Removal
k Stop the machine on a level ground and 6. Remove 2 hydraulic oil cooler hose clamps (4).
front and rear frames. 7. Remove 3 rear combination lamp wiring har-
k Lower the work equipment to the ground, ness clamps (5).
and put chocks under the tires. 8. Remove heat insulation plate (6).

2. Remove the engine hood. For details, see

"Removal and installation of engine hood
assembly".
9. Remove wiring harnesses (7) and (8).
3. Remove muffler cover (1).
a Remove the muffler cover since it will 10. Disconnect air conditioner compressor con-
interfere with the engine slings (wire nector CN-E10 (9).
ropes, etc.)
11. Remove air conditioner compressor assembly
(10). [*1]
a Fix air conditioner compressor assembly
36 WA200-6
12. Remove 2 bracket mounting bolts (11). 17. Remove 3 cooling fan motor hose clamps (18).
13. Remove tube clamp (13) and hose clamp (14).

[*2]

between the air aftercooler and intake mani-
fold.
a Remove bracket (12) and air tube and
hose assembly (15) together.
18. Disconnect radiator upper hose (19). [*4]
15. Disconnect fuel hose (16).
16. Disconnect engine ground cable (17) on the

left side of the engine compartment. [*3]
WA200-6 37
19. Remove the mounting bolts of bracket (20). 25. Remove plate (28) on the left side of the
engine compartment.
20. Remove hose clamps (21) and (22). [*5]
26. Remove wiring harness clamp (29).
between the air aftercooler and turbocharger. 27. Disconnect terminal B (30) from the starting
a Remove bracket (20) and air tube and motor.
hose assembly (23) together.
22. Disconnect radiator lower hose (24). [*6]
28. Remove 2 hose clamps (31).
29. Disconnect heater return hose (32).

a Move heater return hose (32) to a place
where it will not be an obstacle.
30. Disconnect wiring harness terminal CN-E07A

(33).
31. Disconnect wiring harness connector CN-ER1

(34).

(35).

(36).
24. Disconnect alternator wiring harness terminals

CN-E02 (26) and CN-E03 (27).
38 WA200-6
34. Remove 2 wiring harness clamps (37) and 2 38. Place bar [1] over the frame. Using lever block
brackets (38) at the left engine mount. [2], sling HST pump assembly (44).
35. Disconnect wiring harness connectors CN-T01 39. Remove 12 damper cover mounting bolts (45).
(39), CN-T01B (40) and CN-T01A (41) at the [*7]
left engine mount. a Do not remove HST pump mounting bolts
(46) to disconnect the HST pump. If the
HST pump is disconnected from the
engine assembly, you cannot see if the
gears are meshed when installing the
engine assembly and the damper may be
damaged consequently.
36. Remove hose clamp (42).
37. Disconnect heater inlet hose (43).

a Move heater inlet hose (43) to a place
where it will not be an obstacle.
WA200-6 39
40. Using the sling, lift up the engine assembly. 45. Lift up engine assembly (53) a little and move it
toward the rear of the machine to disconnect it
41. Remove right and left engine mounting bolts from the HST pump assembly. [*11]
(47) at the rear of the machine. [*8]
46. Lift off engine assembly (53).
42. Remove right and left engine mounting bolts a Check that all the electric wiring and
(50) at the front of the machine. [*9] hydraulic piping are disconnected.
a Loosen adjustment bolts (48) and (49). a When removing the engine, take care that
it will not interfere with the radiator, air
43. Remove 4 engine mounting bolts (51) on each aftercooler and hydraulic oil cooler.
4
of the right and left side of the front of the
Engine assembly: 500 kg
machine to remove right and left brackets (52).
[*10]
44. Using 2 forcing screws [3], disconnect the

engine assembly from HST pump assembly
(44).
40 WA200-6
Installation a Adjust right and left engine mount adjustment

q Carry out installation in the reverse order to bolts (48) and (49) at front of the machine to
removal. the following dimensions and lock them.
Clearance (a): 2 mm
[*1] Clearance (b): 2 mm
Adjust the air conditioner compressor belt tension. Clearance (c): 30 mm
For details, see "Adjusting air conditioner compres- Clearance (d): 50 mm
sor belt tension" in Testing and adjusting. Clearance (e): 7 mm
[*2]
3 Tube clamp (13): 10 ± 2 Nm {1.0 ± 0.2 kgm}
3 Hose clamp (14):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
3 Engine ground cable mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
[*4]
2 Radiator upper hose: Gasket sealant
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} [*11]
a When installing the engine assembly, carefully
[*5] set damper flange (54) to the gear of HST
3 Hose clamp (21): pump boss (55).
10.5 ± 0.5 Nm {1.07 ± 0.05kgm} a When installing the engine assembly, take care
3 Hose clamp (22): not to damage flange (54).
10.5 ± 0.5 Nm {1.07 ± 0.05kgm}
[*6]
2 Radiator lower hose: Gasket sealant
3 Radiator lower hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*7]
2 Damper cover mating face:
Gasket sealant (LG-6)
3 Damper cover mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*8]
3 Right and left engine mounting bolts (47) at
rear of machine:
235 – 285 Nm {23.5 – 29.5 kgm}
[*9] [*10]
3 Right and left engine mounting bolts (50) at
front of machine:
235 – 285 Nm {23.5 – 29.5 kgm}
3 Right and left engine mount bracket mount-
ing bolts (51) at front of machine:
98 – 123 Nm {10.0 – 12.5 kgm}
WA200-6 41
q Bleeding air
circuit".

and lubricants")
42 WA200-6
Removal and installation of 4. Remove right and left stays (3), (4) and (5).
engine front oil seal assembly 1
Special tools
New/Remodel
Necessity
Sketch
Q'ty
1 795-799-6400 Seal puller t 1

A
6 790-331-1120 Wrench (angle) q 1
Removal
k Stop the machine on a level ground and 5. Remove air conditioner hose clamp (6).
front and rear frames. 6. Remove 2 hydraulic oil cooler hose clamps (7).
stop the engine, apply the parking brake, 7. Remove 3 wiring harness clamps (8).
k Disconnect the cable from the negative (–) 8. Remove heat insulation rubber fixing plate (9).
9. Remove heat insulation plate (10).
1. Loosen the radiator cap and drain the coolant.

(1).
WA200-6 43
10. Remove 3 air conditioner hose clamps (11).
11. Remove air conditioner receiver tank and

bracket assembly (12). [*1]
12. Remove 4 mounting bolts (13) and air condi-

tioner condenser (14).
a Fix air conditioner condenser (14) and air
conditioner receiver (12) to the machine
with ropes.
14. Remove 6 mounting bolts (17) and crankshaft

pulley (18).
13. Put wrench [1] in part (A) (width across flats:

12.7 mm) of tensioner assembly (15) and turn
it in the unwinding direction to decrease the
tension of belt (16).
k Set wrench [1] securely to part (A) of
tensioner assembly (15) before turning
it. (The spring of tensioner assembly
15. Remove engine front oil seal (19).
(15) is strong. If wrench [1] is set
incompletely and turned, it comes off
and that is very dangerous.)
k After removing belt (16), return ten-
sioner assembly (15) slowly and care-
fully.
k Take care not to catch your finger
between the pulley and belt (16) during
work.
44 WA200-6
Installation 2. Crankshaft pulley

1. Using tool A1, install engine front oil seal (19). 1) Install crankshaft pulley (18) to the crank-
a Before installing the engine front oil seal, shaft while setting the dowel hole of the
check that crankshaft end corners and former to the dowel pin of the latter.
seal lip sliding surfaces are free from 2) Tighten mounting bolts (17) according to
housing flaw, burr, fin, rust, etc. the following procedure.
a Before installing the engine front oil seal, 1] Tighten the bolts to 55 ± 5 Nm {5.6 ±
degrease, clean, and dry the seal contact 0.5 kgm} in the diagonal order.
faces of the crankshaft and the seal lip 2] Loosen the bolts by 180°.
surfaces to prevent oil leakage. 3] Tighten the bolts to 55 ± 5 Nm {5.6 ±
a When installing the engine front oil seal, 0.5 kgm} in the diagonal order.
do not apply oil or grease to the crankshaft 4] Retighten the bolts by 90 ± 5°.
and seal lip. a Tool A6 is set for angle tighten-
ing. (See the special tools list.)
a The projection and runout of engine front

oil seal (19) from cover (20) must be in the a When not using angle tightening tool
following range. 5] After steps 1] – 3], make marks on the
q Projection (x): Max. 0.38 mm crankshaft pulley and each bolt with a
q Facial runout (TIR: Total Indicator Read- marker.
ing) (y): Max. 0.25 mm 6] Tighten the bolts by 90 ± 5°.
q Carry out the following installation in the

reverse order to removal.
WA200-6 45
Removal and installation of 6. Remove the 2 flywheel mounting bolts and

engine rear oil seal assembly 1 install guide bolts [2].
Special tools 7. Remove other 6 mounting bolts (3) and lift off
flywheel assembly (4). [*2]
New/Remodel
4 Flywheel assembly: 50 kg
Necessity
Sketch
Q'ty
2 795-799-6500 Seal puller t 1

A
4 795-799-1131 Gear t 1
Removal
k Disconnect the cable from the negative (–) 8. Engine rear oil seal
terminal of the battery. 1) Install tool A2 to the crankshaft.
k If the radiator coolant temperature is high, 2) Tighten tapping screw [3] of tool A2 into
you may scald yourself with the hot cool- the seal carrier of engine rear oil seal (5).
ant. Wait until the coolant is cooled, and 3) Rotate the wrench handle clockwise to
then drain the coolant. remove engine rear oil seal (5).
2. Remove the engine hood assembly. For

engine hood assembly".
3. Remove the engine assembly. For details, see

"Removal and installation of engine assembly".
4. Remove 8 mounting bolts (1) and damper

flange (2). [*1]
5. Install eyebolt [1] to the damper mounting bolt

hole and sling flywheel assembly (4).
46 WA200-6
Installation 4. Using tool A2, install engine rear oil seal (5) to
flywheel housing (7).
1. Keep pilot [4] installed to engine rear oil seal a When installing engine rear oil seal (5),
(5) until it is inserted in the crankshaft. take care not to bend it.
a Before installing the engine rear oil seal, a Extrusion of engine rear oil seal (5) (x):
check that crankshaft end corners and Max. 0.38 mm
seal lip sliding surfaces are free from
housing flaw, burr, fin, rust, etc.
a Before installing the engine rear oil seal,
degrease, clean, and dry the seal contact
faces of the crankshaft and the seal lip
surfaces to prevent oil leakage.
a When installing the engine rear oil seal, do
not apply oil or grease to the crankshaft
and seal lip.
2. Insert pilot [4] in crankshaft (6) and push

engine rear oil seal (5) into flywheel housing
(7).
3. Push in engine rear oil seal (5) further and then

pull out pilot [4]. q Carry out the following installation in the
reverse order to removal.
[*1]
a When installing damper flange (2), direct part
(a) as shown below.
WA200-6 47
2 Damper flange mounting bolt (1): q Measuring radial runout

Adhesive (LT-2) a Radial runout: Max. 0.13 mm
3 Damper flange mounting bolt (1): 1) Install the stand to dial gauge [6] and
44.1 – 53.9 Nm {4.5 – 5.5 kgm} install them to flywheel housing [7].
2) Set the dial gauge so that its probe will be
[*2] perpendicular to spigot portion (b) or
a Tighten the 8 flywheel assembly mounting periphery of the flywheel.
bolts in the order shown below. 3) Rotate the flywheel by 1 turn and measure
3 Flywheel mounting bolt: the difference between the lowest and
137 ± 7 Nm {13.97 ± 0.71 kgm} highest values indicated by the dial gauge.
a After rotating the flywheel by 1 turn,
check that the dial gauge indicates
the value at the start of rotation.
q Measuring facial runout

a Facial runout: Max. 0.20 mm
1) Install the stand to dial gauge [6] and
install them to flywheel housing [7].
2) Set the dial gauge so that its probe will be
perpendicular to end face (c) of the fly-
wheel near the periphery.
3) Rotate the flywheel by 1 turn and measure
the difference between the lowest and
highest values indicated by the dial gauge.
a Set tool A4, lock the flywheel with wrench [5], a After rotating the flywheel by 1 turn, check that
and tighten the flywheel mounting bolts. the dial gauge indicates the value at the start
of rotation.
q Bleeding air
circuit".

and lubricants")
48 WA200-6
Removal and installation of 3. Remove 4 breather hose clamps (3) of fuel

cooling fan and fan motor tank.
assembly 1 4. Remove clip (4) and disconnect hose (5) from
Special tools breather (6).
New/Remodel
5. Remove breather (6).
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
A 8 791-415-2002 Remover t 1
Removal
terminal of the battery. 6. Remove 2 wiring harness clamps (7).
1. Open radiator grille (1). 7. Disconnect wiring harness connectors CN-R59

(8) and CN-R29 (9).
8. Disconnect P port hose (10), TC port hose (11)

and T port hose (12).
a Plug the disconnected hoses and ports to
prevent oil leakage.
9. Remove wiring harness clamp (13) and brack-

ets (14) and (15).
10. Remove 4 shroud mounting bolts (16). [*1]
2. Remove cover (2).
WA200-6 49
11. Open cooling fan and fan motor assembly (17). 17. Remove fan guard (26) from shroud (25).
12. Remove cushion (18) from all the periphery of

the shroud.
13. Remove fan guard (19).
14. Move the lock portion of stopper link (20) to

hole (A) of the bracket to remove it from the
bracket.
18. Remove 2 mounting bolts (27) from each of the

right and left sides to separate upper shroud
(25a) and lower shroud (25b) from each other
and remove fan assembly (28).
a Since the inside of the shroud is fitted in
the groove on the ring end of fan assem-
bly (28), fan assembly (28) cannot be
removed unless the shroud is divided.
15. Remove mounting bolt (21), stopper plate (22)

and nut (23). [*2]
19. Remove 4 mounting bolts (29) and remove fan

motor assembly (31) from bracket (30). [*4]
16. Using tool A8, remove cooling fan assembly

(24). [*3]
50 WA200-6
Installation [*4]
q Carry out installation in the reverse order to a Before installing fan motor assembly (31), add
removal. hydraulic oil (for details, see "Table of fuel,
coolant and lubricants") until it flows over plug
[*1] (33) mount hole and then install the plug.
a Adjust clearances (a) – (d) between the side of
the shroud and end of the fan ring as follows.
Clearance (a): 7.5 mm
Clearance (b): 15.5 mm
Clearance (c): 15.5 mm
Clearance (d): 15.5 mm

again.
5
[*2]
Hydraulic oil (For details, see "Table of
3 Nut (23): 98.0 – 127.5 Nm {10 – 13 kgm}
fuel, coolant and lubricants"): Only nec-
a Set the installed position of stopper plate (22)
essary quantity
in the tightening direction of nut (23).
2 Mounting bolt (21): Adhesive (LT-2)
3 Mounting bolt (21):
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
a Check that key (32) is fitted securely to the key
way on the shaft of fan motor assembly (31).
a When installing cooling fan assembly (24), set
its key way to key (32).
WA200-6 51
Removal and installation of fuel 4. Remove 4 fuel tank breather hose clamps (3).
tank assembly 1
5. Remove clip (4) and disconnect hose (5) from
Removal breather (6).
install the lock bar to the frame to fix the 6. Remove fuel tank cap (7).
front and rear frames. a Fuel tank cap (7) must be removed since it
k Lower the work equipment to the ground, interferes with the fuel tank when the latter
stop the engine, apply the parking brake, is removed.
1. Drain the fuel from the fuel tank.

6 Fuel tank: Approx. 177 l (When full)

(1).
7. Remove hose clamps (8), (9) and (10) on the

fuel tank.
8. Disconnect fuel level gauge wiring harness

connector CN-R21 (11) from the bottom of the
machine.
52 WA200-6
9. Pull out radiator drain hose (12) from the 14. Lower transmission jack [1] gradually and
through hole of the fuel tank. remove fuel tank assembly (17).
a Take care extremely that the fuel tank will
10. Disconnect fuel return hose (13) and supply not come off from the transmission jack.
4
hose (14).
Fuel tank assembly:
a Plug the disconnected hoses to prevent
80 kg (excluding fuel)
fuel leakage.
11. Support the fuel tank bottom with the transmis- Installation
sion jack. q Carry out installation in the reverse order to
removal.
12. Remove fuel tank front mounting bolts (15) on
the right and left sides. [*1] [*1], [*2]
3 Fuel tank mounting bolts (15) and (16):
245 – 309 Nm {25.0 – 31.5 kgm}
q Refilling with fuel (Fuel tank)

Add fuel through the fuel filler.
5 Fuel (For details, see "Table of fuel,
coolant and lubricants"):
177 l (When full)
13. Remove fuel tank rear mounting bolt (16) from

the counterweight bottom. [*2]
WA200-6 53
SEN03787-00

© 2007 KOMATSU
All Rights Reserved
54
SEN03788-00
WA200-6
WA200-6 70001 and up

Power train, Part 1
Disassembly and assembly of transfer assembly ........................................................................................... 2
Removal and installation of parking brake assembly .................................................................................... 21
Disassembly and assembly of parking brake assembly ............................................................................... 23
WA200-6 1
Disassembly and assembly of

transfer assembly 1
Special tools
New/Remodel
Necessity
Sketch
Q'ty
1 790-201-2840 Spacer t 1
2 793T-417-1110 Push tool t 1 Q
790-101-5201 Push took kit t 1
790-101-5311 • Plate 1
3
790-101-5221 • Grip 1 3. Brake accumulator
01010-51225 • Bolt 1 1) Disconnect wiring harness connectors
CN-T06 (1), CN-T07 (2), CN-T10 (3) and
793T-417-1120 Push tool t 1 Q
CN-T11 (4).
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
5 799-301-1500 Oil leak tester t 1
8 790-201-3260 Bolt (12 x 1.75 mm) q 2
9 790-102-2900 Puller q 1
10 792-735-2420 Collar t 1
11 790-101-2501 Puller q 1
D
12 790-201-1320 Spacer t 1
13 790-101-3101 Bearing puller q 1
14 793T-417-1130 Push tool t 1 Q
15 790-101-3501 Gear puller q 1
16 790-101-3401 Bearing puller q 1
17 79G-17L-1000 Bar t 1
2) Disconnect clutch port hose (5) and hose
18 795-100-1291 Sleeve driver t 1 clamp.
19 796-430-1110 Push tool t 1 3) Remove the 6 mounting bolts and remove
20 790-470-1410 Collar t 1 brake accumulator and transfer oil filter
21 796-667-1310 Collar t 1 bracket assembly (6).
22 791-126-0130 Push tool t 1
Commercially
23 available Torque wrench q 1
24 790-434-1470 Push tool t 1
Disassembly
1. Draining transfer oil
6 Transfer case: Approx. 6.5 l
2. Related sensors
Remove speed sensor (75).
2 WA200-6
4. HST motor
1) Remove hoses (7) – (10) from HST
motors 1 and 2.
7. Parking brake assembly

1) Remove breather tube (14).
2) Set the transfer assembly to a block with
2) Remove 4 mounting bolts each and lift off the parking brake side up.
HST motor 1 (11) and HST motor 2 (12). 3) Remove coupling (14a) on the parking
brake side.
5. Oil supply pipe

Remove oil supply pipe (13). 4) Remove the mounting bolts. Using tool
D8, remove parking brake assembly (15).
a For disassembly and assembly of the
parking brake assembly, see "Disas-
sembly and assembly of parking
brake assembly".
CPW15393
6. Parking brake control cable

1) Disconnect hose (13a).
2) Remove parking brake control cable (13b)
and bracket (13c) together.
WA200-6 3
8. Hub
1) Remove snap ring (16).
2) Remove hub (17).
AJF00417
10. Piston and spacer

1) Remove piston (20).
9. Belleville springs
1) Turn over the case and remove cage (18)
from the HST motor mounting section.
a Loosen the mounting bolts evenly
and gradually release the belleville
springs, and then remove the cage. AJF00418
q Free height of belleville springs
(4-piece set): 32.8 mm
q Installed height of belleville
springs (4-piece set): 25.6 mm
q Installed load of belleville springs
(4-piece set): 21,500 N {2,190 kg}
2) Put copper plate [1] in the O-ring groove

and remove spacer (21) with flat-head
screwdriver [2].
AJF00416
AJF00418
2) Remove 4 belleville springs (19).

a Check the directions of the belleville
springs.
a The 1st and 4th belleville springs
have white marks.
a When any belleville spring needs to
be replaced, replace all of the 4
springs as a set.
4 WA200-6
11. Clutch discs, plates, and springs 13. Cage assembly

1) Remove 4 discs (22), 5 plates (23), and 4 1) Remove the mounting bolts. Using tool
wave springs (24). D8, remove cage assembly (60).
AJF00420 AJF15394
2) Using bar [3], remove end plate (25). 2) Remove shims (61).
a Check the thickness and quantity of
the shims.
AJF16148
AJF00439
12. Coupling
1) Remove the mounting bolts and holder
(58). 3) Remove dust seal (76) and oil seal (77)
2) Remove coupling (59). from cage (78).
4) Remove outer race (79).
AJF00437
AJF00449
WA200-6 5
14. Spacer 17. Disassembly of HST motor 1 shaft and ring

Remove spacer (62). gear assembly
1) Using tool D9, remove bearing (27).
AJF00450
9JF15396
15. Front case

Remove the mounting bolts. Using tool D8 2) Remove snap ring (29) and sun gear (30).
and bars [4], remove front case (63).
AJF00425
AJF15395

16. Removal of HST motor 1 shaft and ring gear
Remove HST motor 1 shaft and ring gear
assembly (28).
AJF00426
9JF01027
6 WA200-6
4) Supporting ring gear (32) and using tool 19. Disassembly of carrier assembly
D10 and a press, push out HST motor 1 1) Press shaft (39) and remove ball (40) and
shaft (33). pinion shaft (39) from carrier (41).
a Keep the ball carefully.
2) Remove 2 thrust washers (42), planetary
gear (43), and bearing (44) (at 3 places).
AJF15397
AJF00430
5) Remove bearing (34) and spacer (35)

from ring gear (32).
6) Remove snap ring (36) and bearing (37). 20. Holder

1) Remove the mounting bolts and holder
(45).
AJF00428
9JF01029
18. Removal of carrier assembly

Using tool D11, remove carrier assembly (38)
from the dowel pin of the HST motor 1 gear. 2) Remove seal rings (46) and (47) from
holder (45).
9JF15398
AJF00432
WA200-6 7
21. Removal of HST motor 2 gear and bearing 24. Disassembly of output shaft and gear
assembly assembly
Remove HST motor 2 gear and bearing 1) Using tool D11 and tool D13, remove front
assembly (64). bearing (69).
9JF01030
22. Disassembly of HST motor 2 gear and bear- 2) Remove snap ring (70) and output gear
ing assembly (71).
Using tool D9 and tool D12, remove 2 bearings
(66) from HST motor 2 gear (65).
AJF00446
AJF15399
3) Using tool D14 and the press, push rear

bearing (72) out of output shaft (73).
23. Removal of output shaft and gear assembly
1) Remove 2 mounting bolts of cover (67).
2) Remove output shaft and gear assembly
(68) and cover (67).
AJF16142
9JF01031
8 WA200-6
25. Removal of HST motor 1 gear and outer 26. Disassembly of HST motor 1 gear and outer
races races
a Do not remove the HST motor 1 gear 1) Using tool D16, remove 2 outer races (53)
shaft. (If it is removed forcibly and reused, from HST motor 1 gear (52), and then
it can cause a trouble.) remove spacer (54).
1) Using tool D15, remove bearing (50) and
HST motor 1 gear and outer races (51).
AJF16145
9JF06143
2) Remove seal ring (85) from HST motor 1

gear (52).
a If the claw of tool D15 is too thick to put it
between the gear and case, perform the
1] Screw 3 mounting bolts (M12 × 35
mm) [5] into the carrier mounting
holes of HST motor 1 gear (51) by 15
mm. 9JF00845
2] Using tool D15 (3-claw puller), remove
bearing (50) and HST motor 1 gear
and outer race (51).
27. Bearing
1) Remove 2 plugs (48) from shaft (49).
9JF16144
9JF01037
WA200-6 9
2) Insert 2 tools D17 in the plug holes and hit Assembly

them evenly to remove spacer (55) and a Clean the all parts and check them for dirt or
bearing (56) from shaft (49). damage. Coat their sliding surfaces with
power line oil (for details, see "Table of fuel,
coolant and lubricants") before installing.
a Before icing a bearing in dry ice for expansion
fit, drop about 6 cc of power line oil (for details,
see "Table of fuel, coolant and lubricants") onto
it and rotate it 10 turns.
9JF16146
1. Rear case
Press fit outer race (81) to rear case (80).
28. Rear case

Remove outer race (81) from rear case (80). AJF00906
AJF00906
2. Assembly of output shaft and gear assem-
bly
1) Using tool D1 and the press, press fit rear
bearing (72) to output shaft (73) until it
stops.
a After press fitting the bearing, apply
power line oil (for details, see "Table
29. Clutch housing of fuel, coolant and lubricants") to it
1) Using tool D18, remove clutch housing and rotate it.
(26) and 3 pins (83).
2) Remove snap ring (86) from clutch hous-
ing (26).
AJF00452
9JF16147
10 WA200-6
2) Install output gear (71) and snap ring (70).

2 Spline of gear: Grease (LM-G)
9JF01031
AJF00446
4. Assembly of HST motor 2 gear and bearing

assembly
3) Using tool D2 and the press, press fit front Using tool D19, press fit 2 bearings (66) to
bearing (69). HST motor 2 gear (65).
a After press fitting the bearing, apply a After press fitting the bearings, apply
power line oil (for details, see "Table power line oil (for details, see "Table of
of fuel, coolant and lubricants") to it fuel, coolant and lubricants") to them and
and rotate it. rotate them.
AJF00453 AJF16149
3. Installation of output shaft and gear assem- 5. Installation of HST motor 2 gear and bear-
bly ing assembly
1) Place cover (67) on the gear and install Install HST motor 2 gear and bearing assem-
output shaft and gear assembly (68) to the bly (64).
rear case.
2) Install the mounting bolts of cover (67).
a Check that cover (67) does not inter-
fere with the inside surface of the
gear.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt: 9JF01030
98 – 123 Nm {10.0 – 12.5 kgm}
WA200-6 11
6. Assembly of HST motor 1 gear and outer 8. Bearing and HST motor 1 gear
races 1) Using tool D21 and the press, press fit
1) Install seal ring (85) to HST motor 1 gear bearing (56).
(52).
2 Seal ring: Grease (G2-LI)
9JF16151
9JF00845
2) Install spacer (55).
2) Install spacer (54) to HST motor 1 gear

(52).
3) Using tool D20, press fit 2 outer races (53)
to HST motor 1 gear (52).
AJF00913
AJF16150
3) Install the HST motor 1 gear and outer

races (51).
4) Using tool D19 and the press, press fit
bearing (50).
q Projection of bearing from shaft:
7. Installation of HST motor 1 gear and outer 1.71 – 3.35 mm
races
Install O-ring (82) to shaft (49).
2 O-ring: Grease (G2-LI)
9JF16152
AJF00471
12 WA200-6
9. Holder 10. Assembly of carrier assembly

1) Install seal rings (46) and (47) to holder 1) Set planetary gear (43), bearing (44), and
(45). 2 thrust washers (42) to carrier (41) (at 3
2 Seal ring and O-ring: places).
Grease (G2-LI) 2) Install pinion shaft (39) to carrier (41),
matching their ball holes to each other,
and then install ball (40).
AJF00432
AJF00430
2) Install holder (45) and tighten the mount-

ing bolts.
a Set the hole 2 mm in diameter (g) on 11. Installation of carrier assembly
the top of the holder horizontally [Set Install carrier assembly (38), matching it to the
it at 90° to the hole 4.5 mm in diame- dowel pin of the HST motor 1 gear.
ter (h) on shaft (49)].
3 Mounting bolt:
88.2 – 107.8 Nm {9 – 11 kgm}
9JF01041
AJF00914
12. Assembly of HST motor 1 shaft and ring

gear assembly
1) Install bearing (37) to ring gear (32), and
then install snap ring (36).
AJF00484
WA200-6 13
2) Set ring gear (32) to HST motor 1 shaft 5) Install snap ring (31).
(33). Using tool D19 and the press, press
fit bearing (37).
AJF00426
AJF16153
6) Install sun gear (30) and snap ring (29).
3) Install spacer (35) and set bearing (34).
AJF00425
AJF00486
7) Using tool D22, press fit bearing (27) to

HST motor 1 shaft (33).
4) Using tool D19 and the press, press fit
bearing (34).
9JF16155
AJF15154
14 WA200-6
13. Installation of HST motor 1 shaft and ring 2) Install front case (63).
gear 3 Mounting bolt:
Install HST motor 1 shaft and ring gear assem- 98 – 123 Nm {10.0 – 12.5 kgm}
bly (28).
AJF00907
9JF01027
15. Clutch housing

14. Front case 1) Install snap ring (57) to the front case.
a Use the front case and rear case as an
assembly.
a When installing the cases, match the
match marks on their tops to each other.
1) Apply gasket sealant to the rear case
a Apply the gasket sealant to forcing AJF01036
screw contact part (a), similarly to the
dimensions for a bolt hole.
a Apply the gasket sealant so that
dimensions (b) and (c) will be the
same respectively.
a Apply the gasket sealant so that
dimension (e) x dimension ( f ) will be
2 – 5 mm. 2) Install clutch housing (26) and 3 pins (83).
2 Gasket sealant:
ThreeBond 1207B or equivalent
AJF00909
9JF00819
WA200-6 15
16. Clutch discs, plates, and springs 2) Install O-ring and piston (20).
1) Install end plate (25). 2 O-ring: Grease (G2-LI)
AJF00910 AJF00912
2) Install 6 discs (22), 6 wave springs (24), 18. Belleville springs

and 7 plates (23). 1) Set the 1st one of the 4 belleville springs
a Soak the discs in clean power line oil (19) with the white mark side down.
(for details, see "Table of fuel, coolant 2) Set the 2nd and 3rd belleville springs in
and lubricants") for at least 2 minutes the opposite direction to the 1st one. (No
before installing them. marks on the 2nd and 3rd ones)
3) Set the 4th belleville spring with the white
mark side up.
a When any belleville spring needs to
be replaced, replace all of the 4
springs as a set.
AJF00420
AJF00417
17. Spacer and piston

1) Install O-ring and spacer (21).
2 O-ring: Grease (G2-LI)
19. Cage
Install cage (18).
a Tighten the mounting bolts evenly and
gradually.
AJF00911 q Installed load of belleville springs
(4-piece set): 21,500 N {2,190 kg}
3 Mounting bolt:
245 – 308 Nm {25.0 – 31.5 kgm}
16 WA200-6
22. Parking brake assembly

1) Install 2 dowel pins (85) from the parking
brake assembly.
AJF00416
AJF00915
20. Operation test of transfer clutch

Using tool D5, apply air pressure to transfer
clutch disengagement port (m).
a When the air pressure is applied and the 2) Install parking brake assembly (15).
transfer clutch is disengaged, it is operat- a After the all internal teeth of the disc
ing normally. are meshed with the spline and the
q Clutch disengaging air pressure: clearance between the parking brake
1.52 MPa {15.5 kg/cm2} housing and transfer case is elimi-
nated, tighten the mounting bolts.
a If the mounting bolts are tightened
while there is clearance between the
parking brake housing and transfer
case and the internal teeth of the disc
are shifted from the spline, the disc
AJF00515 will be broken. Accordingly, remove
the dowel pins and check securely in
advance that there is not clearance.
a Do not reuse the gasket but replace
it.
a Install the coupling after "Adjusting
pre-load on output shaft taper roller
bearing".
21. Hub 3 Mounting bolt:
1) Turn over the transfer assembly and install 98 – 123 Nm {10.0 – 12.5 kgm}
hub (17).
2) Install snap ring (16).
2 Spline of output shaft:
Lubricant containing molybde-
num disulfide (LM-P)
AJF00497
AJF00415
WA200-6 17
23. Cage assembly

1) Press fit outer race (79) to cage (78).
2) Using tools D3 and D4, press fit oil seal
(77) and dust seal (76) to cage (78).
2 Lips and clearances of oil seal and
dust seal: Silicone grease (Three-
Bond 1855 or equivalent) AJF00498
AJF00449
9JF00844
9JF00846
4) Calculate shim thickness ( t ) .
q Shim thickness (t) = Average of clear-
ance (k) + (0.15 mm to 0.20 mm)
5) Insert selected shims (61) between cage
(78) and the front case.
6) Tighten the cage mounting bolts.
3 Mounting bolt:
24. Adjusting pre-load on output shaft taper 98 – 123 Nm {10.0 – 12.5 kgm}
roller bearing
1) Install cage (78) without inserting any
shim.
3 Mounting bolt:
4.80 ± 0.98 Nm {0.5 ± 0.1 kgm}
2) Rotate the output shaft 20 turns and check
the tightening torque of the mounting bolts AJF00499
tightened in step 1).
a If the tightening torque has changed,
repeat steps 1) and 2), and then
check again.
3) If the tightening torque has not changed,
measure the clearances at 3 places ( j ) of
cage (78) and obtain average ( k ) .
a To confirm that the bearing is not
leaning, check that the dispersion of
clearances at 3 places ( j ) is 0.15 mm
or less. If the dispersion is large, the
bearing is not installed normally or
there is another cause. In this case,
eliminate the cause and reduce the
dispersion to 0.15 mm or less.
18 WA200-6
7) Install holder (58) and the holder mounting 3) Install coupling (14a) on the parking brake
bolt to the output shaft. side.
8) Set tool D23 to the holder mounting bolt 2 Spline of coupling:
and measure the rotating torque of the Molybdenum disulfide
output shaft. grease (LM-G)
a Measure the rotating torque without 4) Install breather tube (14).
installing the front and rear couplings.
q Rotating torque of output shaft:
3.9 – 5.9 Nm {0.4 – 0.6 kgm}
9JF16156
26. Parking brake control cable

1) Install parking brake control cable (13b)
and bracket (13c) together.
25. Coupling 2) Connect hose (13a).
1) Install coupling (59) on the cage side.
2 Spline of coupling:
Molybdenum disulfide grease
(LM-G)
2) Install holder (58) and tighten the mount-
ing bolt.
AJF00504
27. Oil supply pipe

Install oil supply pipe (13).
WA200-6 19
28. HST motor

1) Sling and install HST motor 2 (12).
2 Spline of HST motor 2:
Molybdenum disulfide
lubricant (LM-G)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
2) Sling and install HST motor 1 (11).
a Do not apply LM-G to the spline of
HST motor 1.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
3) Connect wiring harness connectors CN-

T06 (1), CN-T07 (2), CN-T10 (3) and CN-
T11 (4).
AJF00504
3) Install hoses (7) – (10) to HST motors 1

and 2.
30. Speed sensor

Install speed sensor (75).
AJF00504
29. Brake accumulator

1) Install brake accumulator and transfer oil
filter bracket assembly (6) with the 6
mounting bolts.
2) Connect clutch port hose (5) and fix it with
the clamp. 31. Refilling with oil
Refill the transfer case with oil.
5 Transfer case: Approx. 6.5 l (TO10)
20 WA200-6
Removal and installation of 4. Pull out cotter pin (3) and remove pin (4) to dis-
parking brake assembly 1 connect parking brake cable yoke (5). [*2]
Special tools 5. Disconnect suction hose (6) of transfer lubri-

cating oil pump.
New/Remodel
Necessity
Sketch
Q'ty
D 8 790-201-3260 Bolt (12 x 1.75 mm) q 2

AJF00504
Removal
k Disconnect the cable from the negative (–) 6. Remove coupling (7).
terminal of the battery. a Prepare an oil receiving pan since oil may
leak.
1. Drain the transfer oil.
6 Transfer case: Approx. 6.5 l
2. Remove rear drive shaft (1). [*1]
AJF16208
AJF00504
7. Remove the parking brake mounting bolts.

Using too D8, remove parking brake assembly
(8). [*3]
3. Set parking brake lever (2) in the OFF

(Release) position. (Push down the lever fully
in the direction of the arrow.
AJF16208
AJF00504
WA200-6 21
Installation
removal.
[*1]
3 Rear drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
a Precautions for installing rear drive shaft

1) Check that the key of the spider cap is fit-
ted to the key way of the mating yoke and
then tighten the mounting bolts.
2) Check that the lateral runout of the rear
axle and transfer from each other is 3 mm
or less.
3) If the runout in 2) is 3 mm or larger, adjust
the transfer cushion and transfer mount to
reduce the runout.
[*2]
a After installing the parking brake, open cotter
pin (3) to 180° to fix.
[*3]
a Using tool D8, install parking brake assembly
(8).
3 Parking brake mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
q Refilling with oil (Transfer case)

again.
5 Power line oil: Approx. 6.5 l (TO10)
22 WA200-6
Disassembly and assembly of 2. Plates, discs, and springs

parking brake assembly 1 1) Remove 2 clamping bolts (3) and 2 spac-
ers (4).
Special tools a Since the spring tension is applied,
loosen the 2 clamping bolts evenly.
New/Remodel
Necessity
Sketch
Q'ty

790-101-5311 • Plate 1 AJF00509
3
790-101-5221 • Grip 1
01010-51225 • Bolt 1
D
793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
24 790-434-1470 Push tool t 1
2) Remove 5 plates (5), 4 wave springs (6),
Disassembly and 4 discs (7).
1. Strainer
1) Remove cover (1).
AJF00510
AJF00507
3. Cam plate
Remove cam plate (8).
2) Remove strainer (2).
AJF00511
AJF00508
WA200-6 23
4. Ball 6. Pin
Remove 6 balls (9). Remove pin (12).
7. Dust seal and oil seal

Remove dust seal (13) and oil seal (14).
AJF00512
AJF00517
5. Lever
1) Remove the mounting bolt and lever (10).
8. Oil seal and bearings

1) Remove oil seal (15).
2) Remove 2 bearings (16) from parking
brake case (17).
AJF00513
AJF00522
2) Remove lever (11).
AJF00514
24 WA200-6
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
power line oil (for details, see "Table of fuel,
coolant and lubricants") before installing.
a Do not reuse the gasket but remove it com-
pletely. 9JF00852
1. Oil seal and bearings

1) Install 2 bearings (16) to parking brake
case (17).
2) Install oil seal (15).
2 Oil seal: Grease (G2-LI)
(Although the gasket is fitted to the park-
ing brake fitting face in the drawing, per- 3. Pin
form the work without fitting the gasket.) Install pin (12).
a Install the pin with the grooved part out-
ward.
a Check that dirt is not sticking to the ball
groove and inside of the housing.
(Although the gasket is fitted in the drawing,
perform the work without fitting the gasket.)
AJF00522
AJF00523
2. Oil seal and dust seal

Using tools D3 and D4, press fit oil seal (14)
and dust seal (13).
2 Lips and clearances of oil seal and dust
seal: Silicone grease (ThreeBond
1855 or equivalent)
4. Lever
Install levers (11) and (10).
(Perform the work with the gasket removed.)
9JF00851
AJF00524
WA200-6 25
a When installing the levers (11) and (10), a Move cam plate (8) several times so
match their match marks (a) and (b). that balls (9) will be fitted to grooves
2 Mounting bolt: Adhesive (LT-2) (c) of cam plate (8).
3 Mounting bolt: a Check that the cam plate does not
27 – 34 Nm {2.8 – 3.5 kgm} hitch on the housing.
AJF00525 9JF00853
5. Balls 7. Plates, discs, and springs

Install 6 balls (9). 1) Install 4 discs (7), 4 wave springs (6), and
a Check that dirt is not sticking to the balls. 5 plates (5).
(Perform the work with the gasket removed.) a Soak the disc in clean power line oil
(for details, see "Table of fuel, coolant
and lubricants") for at least 2 minutes
before installing them.
a Check that dirt is not sticking to the
discs and plates.
(Perform the work with the gasket
AJF00512 removed.)
AJF00510
6. Cam plate
Install cam plate (8).
a Check that dirt is not sticking to the ball
grooves, inside of parking brake housing,
cam plate, discs, and plates.
(Perform the work with the gasket removed.)
AJF00511
26 WA200-6
2) Using tool D24, press plate (5) lightly with 2) Install the O-ring and cover (1).
a press and install 2 spacers (4) and 2 2 O-ring: Grease (G2-LI)
lock bolts (3). 3 Mounting bolt:
a Take care not to press plate (5) too 98 – 123 Nm {10.0 – 12.5 kgm}
much and not to damage it.
a Press plate (5) until it is flush with the
parking brake case.
a Move the lever and check that it
returns normally.
2 Lock bolt: Adhesive (LT-2)
3 Lock bolt: AJF00507
19.6 – 27.4 Nm {2.0 – 2.8 kgm}
(Perform the work with the gasket
removed.)
AJF16158
8. Strainer
1) Install strainer (2).
AJF00508
WA200-6 27
SEN03788-00

© 2007 KOMATSU
All Rights Reserved
28
SEN03789-00
WA200-6
WA200-6 70001 and up

Power train, Part 2
Removal and installation of front axle assembly ............................................................................................. 2
Removal and installation of rear axle assembly.............................................................................................. 4
Disassembly and assembly of axle housing assembly ................................................................................... 7
Disassembly and assembly of differential assembly..................................................................................... 15
WA200-6 1
Removal and installation of front 3. Remove work equipment upper cover (2).
axle assembly 1
Removal
rear frames.
and set chocks under the tires.
k Release the residual pressure in the brake
accumulator circuit. For details, see
"Releasing remaining pressure in hydraulic
circuit".
1. Raise the chassis with the work equipment and 4. Disconnect wiring connector CN-F14 (3).
set stands [1] under the frame in front of the
front wheels to float the front of the chassis. 5. Disconnect brake hose (4).
AJF00641 AJF00644
2. Lift off front wheel (1). [*1] 6. Disconnect front drive shaft (5). [*2]
a Lift off the front wheel on the other side
similarly.
4 Front wheel (1 side): 210 kg
AJF00645
AJF00642
2 WA200-6
7. Sling front axle assembly (6) temporarily and Installation

support it on jack [2]. Remove the 4 mounting q Carry out installation in the reverse order to
bolts on both sides and front axle assembly removal.
(6). [*3]
4
[*1]
Front axle assembly: 530 kg
3 Front wheel mounting bolt:
785 – 980 Nm {80 – 100 kgm}
[*2]
a When installing the drive shaft, check that the
key way of the spider cap is fitted to the key
way of the mating yoke, and then tighten the
AJF00646 mounting bolts.
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 Front axle mounting bolt:
785 – 980 Nm {80 – 100 kgm}
q Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
WA200-6 3
Removal and installation of rear 5. Disconnect brake hose (2) from the left inside
axle assembly 1 of the frame.
Removal
rear frames.
stop the engine, apply the parking brake, AJF00650
and set chocks under the tires.
k Release the residual pressure in the brake
accumulator circuit. For details, see
"Releasing remaining pressure in hydraulic
circuit".
1. Raise the chassis with the work equipment and

set stands [1] under the frame in front of the 6. Disconnect grease supply tube (3).
rear wheels to float the rear of the chassis.
2. Support the counterweight on jack [2].
3. Set blocks [3] between top of each side of the

rear axle and the rear frame.
AJF00650
AJF00647
7. Remove rear drive shaft (4). [*2]
4. Lift off rear wheel (1). [*1]

a Remove the right and left fenders. AJF00651
a Lift off the rear wheel on the other side
similarly.
4 Rear wheel (1 side): 210 kg
AJF00648
4 WA200-6
8. Remove the bolts and coupling (5). [*3] 12. Lower the crane and jack [5] simultaneously to
a Remove coupling (5) so that dust seal (9) remove rear axle assembly (7).
4
in step 11 will not be damaged.
Rear axle assembly: 500 kg
AJF00652
AJF16163
9. Secure support (6) and both sides of the rear

axle with lever block [4].
10. Sling rear axle assembly (7) temporarily, sup-

port it on jack [5], and remove the mounting
bolts of support (6). [*4]
AJF16162
11. Pull out the rear axle assembly toward the rear
of the chassis and disconnect it from the rear
frame assembly.
a Take care not to damage dust seal (9) of
rear frame (8).
WA200-6 5
Installation
removal.
[*1]
3 Rear wheel mounting bolt:
785 – 980 Nm {80 – 100 kgm}
[*2]
a Check that the radial runout of the rear axle
from the transfer in lateral direction is not
larger than 3 mm. If it is larger than 3 mm,
reduce it by moving the transfer mount.
key way of the spider cap is fitted to the key
mounting bolts.
3 Rear drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
2 Coupling mounting bolt: Adhesive (LT-2)
3 Coupling mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
[*4]
3 Support mounting bolt:
785 – 980 Nm {80 – 100 kgm}
q Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, "Bleeding air from
brake circuit".
6 WA200-6
Disassembly and assembly of 2. Axle assembly

axle housing assembly 1 Set the axle assembly on block [1].
a Set block [1] so that the axle assembly will
Special tools not lean when the housing assembly on
one side is removed.
New/Remodel
Necessity
Sketch
Q'ty
793T-623-1170 Push tool t 1 Q

793T-422-1230 Push tool t 1 Q AJF00623
1
793T-423-1110 Push tool t 1 Q
792T-446-1150 Push tool t 1 Q
793T-422-1240 Seal support t 2 Q
2 793T-423-1120 Seal support t 2 Q
01016-50860 Bolt t 6
793T-659-1110 Push tool t 1 Q
3
790-201-2750 Spacer t 1
3. Axle housing assembly
4 793T-423-1150 Holder t 1 Q
1) Sling axle housing assembly (1) tempo-
790-101-5201 Push tool kit t 1 rarily and remove the housing mounting
H 790-101-5271 • Plate 1 bolts.
5
790-101-5221 • Grip 1 a When removing both axle housing
01010-51225 • Bolt 1 assemblies, make match marks on
6 790-101-3101 Bearing puller q 1 the housings and differential case so
7 790-101-3501 Gear puller q 1 that the housing assemblies will not
be mistaken.
791T-465-1130 Push tool t 1 Q
8 2) Remove axle housing assembly (1).
790-201-2670 Plate t 1
9 799-501-1120 Pin t 1
10 790-445-5980 Guide bar t 1
11 Commercially Dial gauge q 1

available
12 79A-264-0021 Push-pull scale q 1
AJF00624
Disassembly
a The following photos and illustrations show the
front axle housing as an example.
1. Draining oil
6 Axle (Each of front and rear axles): 18 l
3) Set axle housing assembly (1) with the
planetary carrier side up.
AJF00625
WA200-6 7
4. Planetary carrier assembly 5. Axle shaft

1) Remove axle shaft mounting bolt (2). 1) Sling axle housing assembly (5) about 20
mm.
AJF00626
AJF00629
2) Remove planetary carrier assembly (3).

2) Apply tool H5 to the end of axle shaft (6)
and drive out the shaft with a copper ham-
mer [2].
a The bearing on the planetary carrier
side will come off.
AJF00627
AJF16164
3) Remove shim (4).

a Record the thickness and quantity of
the shims.
6. Axle shaft bearing

a Do not heat the bearing to remove it or cut
it with gas.
1) When removing bearing (7) from axle
AJF00628 shaft (6), evenly push in part (a) around
the oil seal and sleeve (8) with a screw-
driver toward the flange.
2) Make clearance (b) at the contact part of
bearing (7) and sleeve (8a) to hitch the
claws of the puller.
3) Install tool H6 to the bottom of the bearing
and it securely.
4) Install tool H6 to clearance (b).
5) Tighten the bolts of tool H6 to remove
bearing (7).
8 WA200-6
9JF00881 9JF00882
1) Using tool H9, drive in roll pin (15) of plan-
etary carrier (14) until it is in the range of
shaft (16).
a Take care not to drive in the roll pin
too deep.
9JF16165
9JF00883
7. Axle housing
1) Using tool H7, pull up ring gear (9) and 3
pins (10) evenly to remove them from axle
housing (11).
a Install tool H8 to the bolt end of the
tool H7 to adjust the height.
a Take care that the claws of the tool
H7 will not come off the ring gear.
2) Remove outer races (12) and (13) from
axle housing (11).
AJF16167
AJF16166
WA200-6 9
2) Using tool H10, push out shaft (16) with a Assembly

press. 1. Axle housing and axle shaft
1) Press fit bearing outer races (12) and (13)
to axle housing (11).
AJF16168
9JF00882
3) Pull roll pin (15) out of removed shaft (16).
2) Using tool H1, press fit seal (8) and bear-

ing (7) to axle shaft (6) simultaneously.
a Press fit the seal and bearing until oil
seal sleeve (8a) is flush with shaft
end (c), and then check that there is
AJF00634 not clearance between oil seal sleeve
(8a) and bearing (7).
4) Remove pinion gear (17), bearings (18), 9JF00884

and spacer (19) from planetary carrier
(14).
3) Install tool H2 under oil seal (8).

AJF00635 a Adjust tool H2 so that its top will
lightly touch oil seal (8) and the clear-
ance will be even.
9JF00885
10 WA200-6
2. Axle shaft bearing 3. Selecting shims

1) Erect axle shaft (6) on the block and fix it 1) After bearings (7) and (20) are fitted well,
securely. measure the turning force of hole (d) of
2) Sling axle housing (11) vertically, and then axle housing (11).
lower it slowly. a Do not install planetary carrier (14).
a Install the front axle, matching it to the q Turning force (Not static friction, but
oil seal, and insert the axle housing dynamic friction)
by utilizing its weight. (Including seal resistance)
2 Fitting part of oil seal and bearing Front axle:17.6 – 44.1 N {1.8 – 4.5 kg}
(front axle): Axle oil (AXO80) Rear axle:14.7 – 44.1 N {1.5 – 4.5 kg}
a After installing the housing, leave tool
H2 installed until step 4). a If the turning force is below the stan-
3) Using tool H3, press fit bearing (20) to dard value, press fit the bearings
axle shaft (6). again and perform the work in step 1).
a Press fit the bearing, turning the axle a If the turning force exceeds the stan-
housing with the hand. dard value, adjust it according to fol-
2 Outside of bearing: lowing steps 2) – 4).
Axle oil (AXO80)
4) Remove tool H2 horizontally.
a Check that oil seal (8) does not lean.
a Check that the clearance between
axle housing (11) and oil seal (8) is
0.2 mm or less.
9JF00886
WA200-6 11
2) Hold 2 parts of axle shaft and housing 7) After determining the shim thickness,
assembly (5) and sling it by 20 – 30 mm, remove planetary carrier (14).
as you installed the axle housing.
3) Rotating axle shaft (6), hit the flange with
a copper hammer in the direction of the
arrow several times to drive out axle shaft
(6).
4) Adjust the turning force to the standard
value according to step 1).
1) Install spacer (19) in planetary carrier (14).
a Insert the spacer from (g) side of
planetary carrier (14) before installing
gear (17).
AJF00901
2) Raise spacer (19), then install gear (17)

5) Install planetary carrier (14) to the spline and bearings (18).
of axle shaft (6) without the gear and place
tool H4.
a Just place tool H4 on planetary carrier
(14). Do not tighten the bolt.
6) Using a depth micrometer, measure dis-
tance (e) from the end of tool H4 to the
end of the axle shaft. AJF00635
a Subtract thickness (t) of tool H4 from
distance (e), and let the result be
(e – t).
q Shim thickness = (e – t) +0.05
+0
12 WA200-6
3) Using tool H10, press fit shaft (16) to plan- 5. Ring gear
etary carrier (14). Install ring gear (9) to axle housing (11) and
a When press fitting, match pin holes insert 3 pins (10).
(f). a Match the pin holes of the housing and
2 Shaft: Axle oil (AXO80) ring gear.
AJF16169 AJF00638
a Matching the holes of shaft (16) and 6. Planetary carrier assembly

roll pin (15), drive roll pin (15) so that 1) Install shim (4) selected in step 3 to the
it will be flush with planetary carrier end of the axle shaft.
(14).
AJF00628
AJF00637
2) Sling and install planetary carrier assem-

4) Hit the end of shaft (16) and the differen- bly (3).
tial side of gear (17) lightly to push back k When installing the planetary car-
the bearing and check that the gear rier, take care not to catch your fin-
rotates smoothly. gers in the gear.
9JF00890 AJF00639
WA200-6 13
3) Tighten mounting bolt (2).

a Degrease and clean the bolt hole of
the axle shaft and mounting bolt.
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
a Clean the shaft end and planetary AJF16171
c ar rier s pline thoroughly before
installing.
7. Axle housing assembly

AJF00626 1) Degrease and clean the mating faces of
the axle housing and differential housing
and apply gasket sealant all over them.
2 Mating faces of housings:
Gasket sealant
(LOCTITE 515 or equivalent)
2) Sling axle housing assembly (1) horizon-
tally and install it carefully, matching it to
4) Install tool H11 to axle housing (11) and the spline grooves of the sun gear shaft.
measure the end play of the planetary car-
rier.
q End play of planetary carrier:
0 – 0.1 mm
AJF00624
AJF16170
3) Tighten the axle housing mounting bolts in

the diagonal order.
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
5) Rotate axle housing (11) 10 or more turns
to fit it. Then, using tool H12, measure the • Refilling with oil (Axle housing)
starting torque at the mounting bolt hole of Tighten the drain plug and add axle oil through
the axle housing assembly. the oil filler to the specified level, and then
q Starting torque (including seal resis- check the oil level.
tance)
Front axle: 39.2 – 63.7 N {4.0 – 6.5 kgm} 5 Axle oil (Each of front and rear):
Rear axle: 34.3 – 63.7 N {3.5 – 6.5 kgm} 18 l (AXO80)
a If the starting torque exceeds the
above range, adjust it again, referring
to "3. Selecting shims" above.
14 WA200-6
Disassembly and assembly of 4. Axle housing

differential assembly 1 1) Remove both axle housings (1). For
details, see "Disassembly and assembly
Special tools of axle housing".
New/Remodel
Necessity
Sketch
Q'ty
13 799-301-1500 Oil leak tester t 1 AJF00527

14 797-101-1211 Wrench t 1
15 793-615-1100 Wrench t 1
16 793T-422-1220 Push tool t 1 Q
17 797T-423-1320 Push tool t 1 Q
18 792T-413-1130 Push tool t 1 Q
19 793-520-2202 Installer q 3
20 790-190-1500 Pump assembly t 1
21 799-101-5210 Nipple t 1 2) Remove 2 thrust washers (5) and thrust
22 793T-422-1611 Plate t 1 Q plate (6).
23 791T-465-1210 Push tool t 1 Q 3) Lift off rear axle support (7).
24 790-201-3260 Bolt (12 x 1.75 mm) q 2
H 25 791-615-2130 Sleeve t 1
26 Commercially Puller q 1
available
27 79G-05V-1400 Bar t 1
28 792T-413-1120 Push tool t 1 Q
9JF00854
29 Commercially Depth gauge q 1
available
Commercially
30 available Torque wrench q 1
Commercially
31 available Dial gauge q 1
32 790-201-2830 Spacer t 1
33 791-126-0211 Adapter t 1
Commercially 4) Remove packing (8) and bushing (9) from
34 available Depth micrometer q 1
rear axle support (7).
Disassembly
1. Draining oil
6 Axle (Each of front and rear axles): 18 l
2. Brake piping
9JF00855
Remove brake tube and hose assembly (2).
3. Rear axle support (Only rear axle)

1) Remove grease tube (3).
2) Remove cover (4).
the shims.
WA200-6 15
5. Axle oil temperature sensor (Only front 7. Brakes

axle) a Remove both brakes according to the fol-
1) Remove cover (10). lowing procedure.
2) Remove axle oil temperature sensor (11). 1) Remove sun gear shafts (14).
(The shape of the cover in the figure is dif-
ferent more or less from the shape of the
actual cover.)
AJF00532
AJF00530
2) Remove 2 inside hexagon bolts (15) and

outer plate (16).
6. Differential assemblies
Place and stabilize differential assemblies (12)
and (13) on blocks.
a (12): Front differential
(13): Rear differential
AJF00533
AJF00528
3) Remove 2 discs (17), 1 plate (18), and 4

wave springs (19).
AJF00534
AJF00529
16 WA200-6
4) Using tool H13, supply air to the brake 10. Removal of long cage assembly (Only front
port to remove piston (20). differential)
k Do not stand in front of the piston. 1) Remove coupling (23).
(Check that there is no person in a Remove the coupling protector only
front of the piston.) when it needs to be removed.
a Supply air slowly. 2) Remove long cage assembly (24).
AJF16172 AJF00536
5) Remove seal (87) from piston (20). 11. Disassembly of long cage assembly (Only
front differential)
9JF00879
AJF00537
8. Top cover
Remove the mounting bolts, and then remove
top cover (21), using tool H24. 2) Using tool H23, push shaft (26) with a
press to remove it from long cage (27).
9. Slack adjuster
Remove 2 slack adjusters (22).
AJF16174
AJF16173
WA200-6 17
3) Remove snap ring (28) and ring (29), and 13. Removal of rear cage assembly (For rear
then remove bearing (30) from long cage differential)
(27). 1) Before removing cage assembly, loosen
the mounting bolts of coupling (41).
2) Remove the mounting bolts. Using tool
H24, remove rear cage assembly (42).
a Record the thickness and quantity of
the shims.
9JF00857
AJF16177
12. Removal of front cage assembly (Front dif-

ferential)
1) Using tool H14, loosen nut (31) before
removing the cage assembly.
14. Disassembly of front cage assembly (For

front differential)
1) Remove nut (31) and holder (33).
AJF16175
9JF00858
2) Remove the mounting bolts. Using tool

H24, remove front cage assembly (32).
the shims.
2) Using tool H25, push out pinion gear
assembly (81) with a press.
AJF16176
AJF00541
18 WA200-6
3) Remove spacer (34) and bearing (35) 2) Remove oil seal (82).
from pinion gear (36).
AJF00545
9JF00859
3) For the further disassembly procedure for

4) Remove bearing (37), outer races (38) the rear cage assembly, see steps 2) – 4)
and (39) from cage (40). in "14. Disassembly of front cage assem-
bly" shown above.
16. Bearing carriers

1) Sling differential carrier assembly (43)
temporarily.
9JF00860
AJF00546
15. Disassembly of rear cage assembly (For

rear differential)
1) Remove coupling (41).
a Remove the coupling protector only
when it needs to be removed.
2) Remove the mounting bolts and both
bearing carriers (44), using tool H24.
a Make marks on both bearing carriers
so that they will not be mistaken.
the shims.
AJF00544
AJF16179
WA200-6 19
3) Remove seal (84) and ring (85) from each 18. Disassembly of standard differential carrier
bearing carrier (44). assembly
4) Remove outer race (86). a When keeping the parts on both sides,
make marks on them so that they will not
be mistaken.
1) Remove 12 mounting bolts (46).
a Do not remove 4 mounting bolts (47)
of spider shaft (a).
AJF00598
AJF00549
17. Removal of differential carrier assembly

Lift off differential carrier assembly (43) from
differential housing (45).
a Take care that the sling will not come off.
a Do not damage the bearing of the differen-
tial carrier assembly by hitting it against 2) Remove case and bearing assembly (48).
the differential case. a Before disconnecting the case and
bearing assembly, make match marks
on it and the case.
AJF00548
AJF00550
3) Using tool H26, remove bearing (49) from

case (50).
AJF16180
20 WA200-6
4) Remove washer (51) and side gear (52). 7) Remove side gear (57).
AJF00552 AJF00555
5) Remove pinion gear assembly (53). 8) Remove washer (58).
AJF00554 AJF00556
6) Remove 4 spherical washers (54) and 4 9) Remove 4 mounting bolts, and then
pinion gears (55) from spider shaft (56). remove bevel gear and bearing assembly
(59) from case (60).
AJF00553
AJF00557
WA200-6 21
10) Using tool H26, remove bearing (61) from 2) Using tool H27, remove bearing (64) from
bevel gear (62). bevel gear (65).
AJF16181 AJF16182
19. Disassembly of limited-slip differential 3) Remove washer (66).

assembly (If equipped)
a If the machine is equipped with the lim-
ited-slip differential assembly, disassem-
ble it according to the following procedure.
a When keeping the parts on both sides,
make marks on them so that they will not
be mistaken. AJF00561
1) Remove the 16 mounting bolts and bevel
gear and bearing assembly (63).
a Before disconnecting the bevel gear
and bearing assembly, make match
marks on it and the case.
4) Remove 2 plates (67) and 2 discs (68).
AJF00559
AJF00562
22 WA200-6
5) Remove pressure ring (69). 8) Remove 4 pinion gears (72) from spider
a Insert a finger in the hole on the side shaft (73).
of the case to raise the pressure ring.
AJF00566
AJF00563
9) Remove side gear (74).

6) Remove side gear (70).
AJF00568
AJF00564
10) Remove pressure ring (75).

7) Remove pinion gear assembly (71).
AJF00567
AJF00565
WA200-6 23
11) Remove 2 plates (76) and 2 discs (77). Assembly

a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with axle
oil (AXO80) before installing.
1. Assembly of limited-slip differential assem-

bly (If equipped)
AJF00570 1) Install bearing (79) to case (80).
a Install the bearing by shrink fit at tem-
perature below 100°C or by using tool
H28 and a press.
12) Remove washer (78).

AJF16184
AJF00571
2) Install washer (78).

a Install the washer with the dimpled
side in (up).
13) Using tool H27, remove bearing (79) from

case (80).
AJF00571
AJF16183
24 WA200-6
3) Install 2 discs (77) and 2 plates (76). 5) Install side gear (74).
2 Before installing the discs and a Referring to step 10) below, match
plates, soak them in the axle oil the cut of the inside of the disc to the
(AXO80). oil groove of the side gear.
AJF00570 AJF00568
4) Install pressure ring (75). 6) Install 4 pinion gears (72) to spider shaft
(73).
AJF00567
AJF00566
7) Install pinion gear assembly (71).
AJF00565
WA200-6 25
8) Install side gear (70).
AJF00577
AJF00564
11) Selection of thickness of plate

9) Install pressure ring (69). 1] Using tool H29, measure distance (d)
between case (80) and plate (67).
a Distance (d) is the clearance
between the case and plate.
2] Select the thickness of the plate so
that distance (d) will be 0.2 – 0.6 mm.
a Replace the plates on both sides
AJF00563 so that their thickness (total of 2
pieces) will be the same and
assemble them according to the
procedure 3) and after, shown
above.
q Varieties of plate thickness:
3.0 mm, 3.1 mm
10) Install 2 discs (68) and 2 plates (67).

a Match cut (b) of the inside of the disc
to oil groove (c) of the side gear.
2 Before installing the discs and
plates, soak them in the axle oil
(AXO80).
AJF16185
AJF00562
26 WA200-6
12) Install bearing (64) to bevel gear (65). 14) Install bevel gear and bearing assembly
a Install the bearing by shrink fit at tem- (63).
perature below 100°C or by using tool a Match the match marks made when
H28 and a press. the assembly was removed.
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
AJF16186
AJF00559
13) Install washer (66) to the back side of the

bevel gear.
side toward the side gear. 15) Adjust the clearance of the side gear in
a When installing the washer, apply the axial direction.
axle oil (AXO80) or grease thinly to it 1] Measure clearance (e) between the
so that it will stuck to the bevel gear. side gear and washer through the
shaft holes on both sides of the lim-
ited-slip differential.
q Clearance (e):
0.13 – 0.36 mm (on both sides)
a If the clearance is out of the stan-
dard range, replace the washer
AJF00614 with new one.
9JF00863
WA200-6 27
16) Measure the no-load operation torque. 2) Install bevel gear and bearing assembly
1] Install sun gear shafts (14) to both (59) to case (60) with the 4 mounting
s i d es o f l im i te d- s l i p d i ffe r en ti a l bolts.
assembly (83). a Match the match marks made when
2] Fix the sun gear shaft on one side the assembly was removed.
and install tool H15 to the sun gear a Install the mounting bolts to the 4
shaft on the other side. places of the spider shaft.
3] Install tool H30 (torque wrench) to 2 Mounting bolt: Adhesive (LT-2)
tool H15 and measure the no-load 3 Mounting bolt:
operation torque. 245 – 309 Nm {25.0 – 31.5 kgm}
a When measuring, let the case
rotate freely.
q No-load operation torque:
Max. 10 Nm {1.0 kgm}
q If the no-load operation torque
exceeds the standard value, dis-
assemble the limited-slip differ- AJF00557
ential again and perform "11)
Selection of thickness of plate"
and "15) Adjust the clearance of
the side gear in the axial direc-
tion".
3) Install washer (58).

side up (toward the side gear).
9JF16187
AJF00556
2. Assembly of standard differential carrier

assembly
1) Install bearing (61) to bevel gear (62).
H28 and a press. 4) Install side gear (57).
AJF16188 AJF00555
28 WA200-6
5) Install 4 pinion gears (55) and 4 spherical 8) Install bearing (49) to case (50).
bushings (54) to spider shaft (56). a Install the bearing by shrink fit at tem-
H28 and a press.
AJF00553
AJF16189
6) Install pinion gear assembly (53).
9) Install washer (51) to case and bearing

assembly (48).
side up (toward the side gear).
a Apply axle oil (AXO80) or grease
AJF00554 thinly to the washer and stick the
washer to the case.
7) Install side gear (52).

AJF00903
AJF00905
10) Install case and bearing assembly (48).
a Match the match marks made when
the assembly was removed.
a Turn over the assembly and tighten
the mounting bolts.
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
WA200-6 29
3) Using tool H24, install shim (87) and both

bearing carriers (44).
a Install the shims of the thickness and
quantity checked when disassem-
bled to each bearing carrier.
a Turning the bevel gear, tighten the
AJF00550 mounting bolts.
2 Bearing: Axle oil (AXO80)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
3. Installation of differential assembly

Sling differential carrier assembly (43) and set
it to the mounting section of differential case.
AJF16190
a Take care that the sling will not come off.
a Do not damage the bearing of the differen-
tial carrier assembly by hitting it against
the differential case.
a Rotate the bearing several turns to

spread axle oil (AXO80) into it.
4) Using tool H12, measure the starting
AJF00546 torque of the bevel gear in the tangential
direction.
q Starting torque:
8.8 – 20.6 N {0.9 – 2.1 kg}
a If the starting torque is out of the stan-
dard range, adjust it by increasing or
decreasing the shim thickness.
q Varieties of shim thickness:
4. Bearing carrier 0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
1) Install outer race (86). a Limit the shim thickness after the
2) Install ring (85) and seal (84) to bearing adjustment to 0.5 – 1.35 mm on each
carrier (44). side.
AJF00598 AJF16191
30 WA200-6
5. Assembly of front cage assembly (For front 4) Erect pinion gear assembly (81) and
differential) install cage assembly (88).
1) Install outer races (39) and (38) to cage 5) Install bearing (37) to pinion gear assem-
(40). bly (81).
H17 and a press.
9JF00865
9JF16193
2) Install bearing (35) to pinion gear (36).

H16 and a press. 6) Install holder (33) and nut (31).
3) Install spacer (34) to pinion gear (36). a Nut (31) should be used a brand new
one.
7) Using tool H14 (See "12. Removal of front
cage assembly"), tighten nut (31) to the
specified torque.
a Secure assembly by gripping the out-
side of the pinion gear in a vise.
9JF16192 3 Mounting nut:
441 – 539 Nm {45 – 55 kgm}
9JS01486
WA200-6 31
8) Apply axle oil to the bearing and rotate the

cage several turns to spread the axle oil to
every part of the bearing, and then mea-
sure the following.
2 Bearing: Axle oil (AXO80)
q End play: 0 – 0.162 mm
q Starting torque at cage mounting hole 9JF16194
(A): 0 – 60.8 N {0 – 6.2 kg}
a If the cage is heavy to rotate, replace
the bearing, and then check the rota-
tion of the cage again.
6. Assembly of rear cage assembly

1) Referring to "5. Assembly of front cage
assembly", steps 1) – 5), assemble the 7. Installation of front cage assembly (For
rear cage assembly. front differential)
2) Install coupling (41) and the holder. Install tool H24 to the differential case assem-
2 Contact surfaces of coupling and bly, and then install shim (89), O-ring, and front
bearing: Lubricant containing cage assembly (32).
molybdenum disulfide (LM-G or a Install the shims of the thickness and
LM-P) quantity checked when disassembled to
3 Mounting bolt: each bearing carrier.
245 – 309 Nm {25.0 – 31.5 kgm} a Install the shims with the thinnest one on
the cage side.
3) Rotate the cage several turns to spread q Adjustment allowance of shims:
the axle oil to every part of the bearing, 0.50 – 1.23 mm
and then measure the following. q Varieties of shim thickness:
q End play: 0 – 0.162 mm 0.05 mm, 0.2 mm, 0.3 mm, 0.6 mm
q Starting torque at cage mounting hole 3 Mounting bolt:
(A): 0 – 60.8 N {0 – 6.2 kg} 98 – 123 Nm {10.0 – 12.5 kgm}
a If the cage is heavy to rotate, replace
the bearing, and then check the rota-
tion of the cage again.
4) Remove coupling (41). Then, using tool
H18, press fit oil seal (82).
5) Install coupling (41) and the holder again. AJF16195
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
32 WA200-6
8. Installation of rear cage assembly 2) If the measured backlash is out of the

Install tool H24 to the differential case assem- standard range, adjust it by moving a part
bly, and then install shim (90), O-ring, and rear of the shims to the opposite side.
cage assembly (42). a Do not change the total thickness of
a For the adjustment of the shims and tight- the shims on both sides.
ening torque, see "7. Installation of front a If the backlash is insufficient, move a
cage assembly". part of shims (g) to the shims ( f ) .
(Move the bevel gear in direction (A)).
a If the backlash is too large, move a
part of shims ( f ) to the shims (g).
(Move the bevel gear in direction (B)).
AJF16196
9JF00868
9. Adjusting backlash
1) Measure the backlash of the bevel gear
with tool H31.
q Standard backlash: 0.20 – 0.33 mm
a Measure the backlash at 3 places on
the periphery of the bevel gear and
check that the dispersion of the mea-
sured values is 0.1 mm or less.
CJH11994
AJF16197
WA200-6 33
10. Testing tooth contact

Apply red lead thinly to the surfaces of the
bevel gear teeth and turn the bevel gear in the
forward and reverse directions, then check the
tooth contact pattern on the bevel gear.
a The center of the tooth contact must be as
follows. 9JF00869
q Middle of tooth height
q Point on tooth at which distance of (x)
from small end (c) is 22 ± 3 mm
a Width (y) of the tooth contact must be 28 ±
3 mm.
a Check that there is not a strong contact at
tip (a), bottom (b), small end (c), or large
end (d). 3) If the bevel pinion is too close to the bevel
gear, the tooth contact pattern is as fol-
lows. In this case, adjust the tooth contact
q Increase the shims of the cage
assembly (on the bevel pinion side) to
move the cage assembly in the direc-
CJH11994 tion of (E).
q Adjust the shims on both sides of the
bearing carrier to move bevel gear in
the direction of (F) close to the bevel
pinion.
a Do not change the total thickness of
the shims on both sides of the bear-
ing carrier.
11. Adjusting tooth contact
1) If the tooth contact pattern is not proper,
adjust the tooth contact.
a Adjust the tooth contact by increasing
or decreasing the shims on both sides
of the bearing carrier (to move the
bevel gear) and the shims of the cage 9JF00870
assembly (to move the bevel pinion).
a After adjusting the tooth contact,
check the backlash again.
2) If the bevel pinion is too far from the bevel
gear, the tooth contact pattern is as fol-
q Decrease the shims of the cage
tion of (C).
the direction of (D) far from the bevel
pinion.
ing carrier.
34 WA200-6
4) If the bevel gear is too close to the bevel 12. Brake

pinion, the tooth contact pattern is as fol- a Install both brakes according to the same
lows. In this case, adjust the tooth contact procedure.
according to the following procedure. 1) Install seal (87) to piston (20).
q Decrease the shims of the cage
tion (C).
the direction of (D) far from the bevel 9JF00879
pinion.
ing carrier.
2 Thinly apply axle oil (AXO80) to the

piston and piston mounting section.
2) Using tool H19, press fit piston (20)
9JF00871 evenly.
a Press fit the piston until it touches the
housing.
a Do not hit the piston with a plastic
hammer, etc. to press fit it. (If it is
press fitted so, it and its O-ring will be
damaged.)
5) If the bevel gear is too far from the bevel

pinion, the tooth contact pattern is as fol-
q Increase the shims of the cage
assembly (on the bevel pinion side) to 9JF16198
tion of (E).
the direction of (F), close to the bevel
pinion.
ing carrier.
9JF00872
WA200-6 35
3) Install 1 disc (17A), 1 disc (17B), 1 plate 5) Install sun gear shaft (14).
(18), 2 wave springs (19A), and 2 wave
springs (19B).
a Install these parts in order of (19A),
(17A), (18), (19B), and (17B).
AJF00532
AJF00904
6) Install bleeder screw (100).

7) Install tool H22.
a You may install tool H22 when check-
ing for brake oil leakage.
a Pile up the 2 springs and match their a Be sure to fit the O-ring to tool H22.
cuts to each other, and then install 3 Mounting bolt of tool H22:
them so that their cuts will be in the 98 – 123 Nm {10.0 – 12.5 kgm}
range of (h) in the brake oil port. 8) Set plate [1] (equivalent to tool H19).
Using tool H13, supply air into the brake
oil port to fit the piston.
k If the air is supplied without setting
plate [1], the piston will jump out,
and that is dangerous.
9JF00877
AJS16199
4) Install outer plate (16) and install 2 inside

hexagon bolts (15).
AJF00533
36 WA200-6
13. Brake oil leakage test a If the oil leaks (If the pressure drops
a Action of the piston of the slack adjuster more than the standard), remove the
lowers pressure during the low-pressure brake piston and check the seals for
leakage test. To prevent this, use tool damage.
H19. a If the hose is moved while the pres-
1) Keep plate [1] (equivalent to tool H19) set. sure is measured, the pressure fluctu-
k If the brake oil leakage test is per- ates. Accordingly, do not move the
formed without setting plate [1], hose.
the piston will jump out, and that is 5) Remove tools H20, H21, and H22 and
dangerous. plate [1] (equivalent to tool H19), and then
2) Install tools H22, H21 and H20 to the perform the test on the opposite side.
brake port and bleed all air from the brake
system through the bleeder. 14. Top cover
a Be sure to fit the O-ring to tool H22. 1) Remove bleeder screw (100) temporarily
3 Mounting bolt of tool H22: and install top cover (21).
98 – 123 Nm {10.0 – 12.5 kgm} 2 Mating face of cover: Adhesive
a Bleed air by operating pump H20. (LOCTITE 515 or equivalent)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
2) Install slack adjusters (22) to the right and
left.
a Take care that the O-rings will not
come off.
AJS16200 3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
3) Perform the low-pressure oil leakage test. AJS00922

a Operate pump H20 to raise the pres-
sure to 98 kPa {1 kg/cm2}.
a Leave the system at 98 kPa {1 kg/
cm2} for 5 minutes and check that the
pressure does not lower at all.
a If the oil leaks (If the pressure drops
more than the standard), remove the
brake piston and check the seals for a For the rear differential, perform "19.
damage. Rear axle support" and after steps.
a If the hose is moved while the pres- a Perform steps 15 – 18 for the front dif-
sure is measured, the pressure fluctu- ferential.
ates. Accordingly, do not move the
hose.
4) Perform the high-pressure brake oil leak-
age test.
a If oil leakage is not detected by the
low-pressure brake oil leakage test,
operate pump H20 to raise the pres-
sure to 4,410 kPa {45 kg/cm2}.
a Leave the system at 4,410 kPa {45
kg/cm2} for 5 minutes and check that
the pressure does not drop more than
98 kPa {1 kg/cm2}.
WA200-6 37
15. Axle oil temperature sensor (Only front 3) Install ring (29) and snap ring (28).
axle)
1) Install axle oil temperature sensor (11).
2 Threads: Gasket sealant (LG-5)
3 Axle oil temperature sensor:
29.4 – 49.0 Nm {3 – 5 kgm}
2) Install cover (10).
3 Mounting bolt: 9JF00874
98 – 123 Nm {10.0 – 12.5 kgm}
AJF00530 4) Using tool H18, press fit oil seal (25).

16. Disassembly of long cage assembly (Only 9JF16202

front differential)
1) Using tool H32, press fit bearing (30) to
shaft (26) with a press.
a Direct the shield side of the bearing
down.
2) Using tool H33, press fit shaft and bearing
assembly (91) to long cage (27).
17. Installation of long cage assembly (For only
front differential)
1) Sling and install long cage assembly (24).
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
2) Install coupling (23).
9JF16201 2 Contact surfaces of coupling and
bearing: Molybdenum disulfide
grease (LM-G) or (LM-P)
3 Mounting bolt:
245 – 309 Nm {25.0 – 31.5 kgm}
38 WA200-6
18. Axle housing 19. Rear axle support

1) Apply a string of LOCTITE 515, 2 – 3 mm 1) Install bushing (9) and packing (8) to rear
in diameter to part (p) of differential hous- axle support (7).
ing (45). a Install the bushing with the chamfered
a Take care that LOCTITE 515 will not part on the axle side and the slit at the
project into hollow parts (r). side position.
a Install the packing with the lip on the
outside of the rear axle support (on
the axle side).
9JF01122
9JF00855
2) Referring to "Disassembly and assembly

of axle housing", sling and install right and
left axle housings (1).
2) Sling and install rear axle support (7).
3) Install thrust plate (6) and 2 thrust wash-
ers (5).
a Clean the mating faces of the thrust
plate and thrust washer thoroughly.
a Install thrust washer (5) with cham-
AJS00923 fered part (h) out.
a Insert a clearance gauge all round the
mating faces of the thrust plate and
thrust washer to check that there is
not a clearance.
2 Periphery of pivot mounting part:
Grease (G2-LI)
2 Mounting bolt:
3) Install brake tube assembly. Adhesive (LOCTITE 262)

3 Mounting bolt:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
9JF01122
WA200-6 39
20. Adjust the shim of cover (trunnion cap) (4).

1) Measure dimension ( k ) of cover (4) with
tool H34 at 4 places on the diagonal lines
and obtain the average.
a Clean the contact face of the depth
micrometer thoroughly.
q Standard average value ( k ) : 9JF16209
19.85 – 20.00 mm
9JF01114 3) Calculate shim thickness ( t ) .

q Shim thickness ( t ) = (m) – ( k )
a Decide the number of the shims by
the calculated shim thickness and the
following table.
q Shim thickness (1 piece): 0.2 mm
Shim thickness Number of shims
0 – 0.07 mm 1
0.08 – 0.27 mm 2
0.28 – 0.47 mm 3
4) Install selected shim (92), and then install

cover (4) again.
2 Cover: Grease (G2-LI)
9JF16203
3 Mounting bolt:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
2) Measure dimension (m) between rear axle 9JF00878

support (7) and thrust washer (5) with tool
H34 at 4 places on the diagonal lines and
obtain the average.
a Clean the contact face of tool H34
(depth micrometer) thoroughly.
q Standard average value (m) (Refer-
ence): 19.65 – 20.00 mm
9JF01117
40 WA200-6
21. Grease tube and brake piping

1) Install grease tube (3).
2) Install brake tube and hose assembly (2).
22. Axle housing

Install both axle housings (1). For details, see
"Disassembly and assembly of axle housing
assembly".
AJF00527
q Refilling with oil (Axle housing)

Tighten the drain plug and add oil through the
oil filler to the specified level.
3 Drain plug:
127.4 – 176.4 Nm {13 – 18 kgm}
3 Oil filler plug:
93.1 – 122.5 Nm {9.5 – 12.5 kgm}
5 Axle oil: (Each of front and rear):
18 l (AXO80)
WA200-6 41
SEN03789-00

© 2007 KOMATSU
All Rights Reserved
42
SEN03790-00
WA200-6
WA200-6 70001 and up

Undercarriage and frame
Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight assembly ....................................................................................11
WA200-6 1
Removal and installation of center 4. Recover the refrigerant (R134a). [*1]

hinge pin 1
6
Special tools Radiator: 17 l
New/Remodel
Necessity
6. Remove operator's cab and floor frame
Sketch
Q'ty
Symbol Part No. Part Name assembly (1). For details, see "Removal and
installation of operator's cab and floor frame
assembly".
1 791-830-1410 Push tool t 1
J 2 791-630-1260 Push tool t 1

Commercially
3 available Clearance gauge q 1
Removal
rear frames.
1. Raise the front part of the chassis with the

work equipment and set block [1] under the
frame at the rear of the front wheels.
2. Set the work equipment horizontally and raise

the rear part of the chassis and set block [1]
under the frame at the front of the rear wheels.
AJF00732
3. Raise the counterweight with hydraulic jack [2],
and set stand [3].

q Precautions for handling refrigerant

k Collect refrigerant (R134a) beforehand. 7. Disconnect all wiring harness clamps (1a)
a Ask professional traders for collecting and between the front frame and rear frame from
filling the refrigerant (R134a). the rear frame.
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness.
Therefore, make sure to wear protec-
tive glasses when collecting or filling
the refrigerant. Collecting and filling AJF00727
work must be conducted by a qualified
person.
k If the radiator coolant temperature is
high, you may scald yourself with the
hot coolant when disconnecting the
heater hoses and draining the cool-
ant. Wait until the coolant is cooled,
and then drain the coolant.
2 WA200-6
8. Disconnect front drive shaft (2) from the trans- 11. Disconnect the PPC hoses (5) – (8) from the
fer. [*2] work equipment valve. [*4]
12. Disconnect port P hose (9) and port T hose

(10).
a Since oil will leak through the discon-
nected hoses and tubes, prepare oil
receivers.
AJF00727
AJF00730
9. Disconnect front brake hose (3) from the hose

bracket of the front frame. [*3]
AJF00727
AJF00730
10. Remove 2 hose clamp bracket mounting bolts

(4) from the front frame.
13. Remove pins (11) from the bottom side of both

steering cylinders. [*5]
AJF00729
AJF00731
WA200-6 3
14. Remove the lower hinge pin. [*6] 4) Remove upper spacer (18).
1) Remove lock bolt (12). a The upper spacer may be removed
2) Remove lower hinge pin (13). after the front frame is disconnected.
AJF00733 AJF00738
15. Remove the upper hinge pin. [*7] 16. Disconnect the front frame and rear frame.
1) Remove mounting bolt (14). [*9]
2) Remove mounting nut (15). 1) Set hand lift truck [4] under bucket (19).
AJF00734 AJF00736
3) Adjust the height of the front frame and 2) Using a bar, etc., raise front frame assem-
rear frame with the hydraulic jack so that bly (20) by 1 – 2 mm to move lower spacer
you can pull out the pin easily, and then (21) from rear frame assembly (22).
remove upper hinge pin (16) and shims a You may raise the front frame assem-
(17). [*8] bly by 1 – 2 mm with a large-sized
a Record the thickness and quantity of crane, if available.
the shims.
9JF00909
AJF00735
4 WA200-6
3) Turn the tires to move front frame assem- 3) Remove retainer (30) and shim (31).
bly (20) forward. a Record the thickness and quantity of
the shims.
4) Remove dust seal (32) from retainer (30).
AJF00737
AJF00742
17. Disassemble the lower hinge of the front

frame. [*10]
1) Remove washer (23). 5) Remove bearing (33a) and spacer (33b).
2) Remove snap ring (24) and then remove
bearing (25) with a push tool etc.
9JF00911
AJF00739
19. Remove 2 bushings (34) from the lower hinge

of the rear frame. [*12]
18. Disassemble the upper hinge of the front
frame. [*11]
1) Remove lower spacer (28).
2) Remove dust seal (29).
AJF00743
AJF00741
WA200-6 5
Installation [*4]
q Carry out installation in the reverse order to a Connect PPC hoses (5) – (8) according to their
removal. band colors shown below.
q Work equipment lever specification: monolever
[*1]
No. Connecting point Band color
a When installing the hoses of the air conditioner
(5) Bucket DUMP Orange
circuit, take care that dirt, dust, water, etc. will
not enter them. (6) Bucket TILT Red
a When installing each air conditioner hose, (7) Lift arm LOWER Blue
check that O-ring (70) is fitted to it. (8) Lift arm RAISE Yellow
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply [*5]
compressor oil for new refrigerant (R134a) a Adjust the shim so that the total of the upper
(DENSO: ND-OIL8 or ZEXEL ZXL100PG and lower clearances between the frame and
(equivalent to PAG46)) to O-ring (70). cylinder will be less than 0.5 mm.
3 Threaded part of hose (M16 × 1.5): q Varieties of shim thickness: 0.5 mm, 1 mm
12 – 15 Nm {1.2 – 1.5 kgm} 2 Inside of bushing on cylinder side and
3 Threaded part of hose (M22 × 1.5): dust seal:
20 – 25 Nm {2.0 – 2.5 kgm} Lubricant containing molybdenum
3 Threaded part of hose (M24 × 1.5): disulfide (LM-P)
30 – 35 Nm {3.0 – 3.5 kgm}
[*10] [*11] [*12]
a Assemble the upper hinge and lower hinge
1. Install 2 bushings (34) to the lower hinge of the
rear frame.
AJF00743
q Charging with refrigerant (R134a)

Charge the air conditioner circuit with refriger-
ant (R134a).
a Charge capacity: 1,200 ± 50 g
[*2]
3 Front drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
key way of the spider cap is fitted in the key
mounting bolts.
[*3]
a Bleed air from the brake. For details, see Test-
ing and adjusting, "Bleeding air from wheel
brake circuit".
6 WA200-6
2. Assemble the upper hinge of the front frame. 4) Press fit dust seal (32) to retainer (30).
1) Using tool J1, press fit bearing (33a) and a Press fit the dust seal with the lip out.
spacer (33b) to the front frame. 2 Lip of dust seal: Grease (G2-LI)
a Since the clearance of bearing (33a)
and spacer (33b) is adjusted properly,
do not change their combination.
a Since bearing (33a) and spacer (33b)
are an assembly, always replace
them as a set.
a Press fit bearing (33a) and spacer 9JF00913
(33b) securely so that a clearance will
not be made between the bearing and
frame.
2 Bearing: Grease (G2-LI)
5) Tighten the mounting bolts of retainer (30)

evenly.
3 Retainer mounting bolt:
9JF16204 3.92 – 5.88 Nm {0.4 – 0.6 kgm}
6) Measure the clearance between retainer
(30) and front frame with tool J3, and then
select shims so that the maximum clear-
ance will be 0.1 – 0.2 mm when the shims
are inserted.
q Standard shim thickness: 1.3 mm
q Varieties of shim thickness:
2) Press fit dust seal (29) to the front frame. 0.1 mm, 0.5 mm
a Press fit the dust seal with the lip out.
2 Lip of dust seal: Grease (G2-LI)
3) Install lower spacer (28).
a Install the spacer with the chamfered
part on the bearing side.
2 Lower spacer:
Lubricant containing molybde- AJF16205
num disulfide (LM-P)
AJF00741
WA200-6 7
7) Insert selected shim (31) and tighten the 6 [*6] [*7] [*8] [*9]
mounting bolts. a Install the upper hinge pin and lower hinge pin
3 Mounting bolt: according to the following procedure.
59 – 74 Nm {6.0 – 7.5 kgm}
1. Set hand lift truck [4] under the bucket and turn
the tires to move the front frame assembly (20)
toward the rear frame.
AJF00745
AJF15388
3. Assemble the lower hinge section of the front

frame.
2) Using tool J2, press fit bearing (25) to the 2. Using a bar, etc., raise front frame assembly
front frame. (20) by 1 – 2 mm to move spacer (21) to the
a Press fit the bearing securely so that spacer of rear frame assembly (22).
a clearance will not be made between a You may raise the front frame assembly
it and frame. by 1 – 2 mm with a large-sized crane, if
2 Bearing: Grease (G2-LI) available.
9JF16206 9JF00909
3) Install snap ring (24) and washer (23). 3. Align the upper and lower pin holes.
a Using a hydraulic jack, adjust the height of
the front and rear frames and align the pin
holes.
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin
holes.
AJF00739
8 WA200-6
4. Install upper spacer (18). 7. Measure clearance (a) between upper hinge
a Install the spacer with the chamfered part pin (16) and rear frame top with a clearance
on the bearing side. gauge, and then select shims so that the maxi-
2 Upper spacer: mum clearance will be less than 0.4 mm when
Lubricant containing molybdenum the shims are inserted.
disulfide (LM-P) q Standard shim thickness: 0.8 mm
q Varieties of shim thickness: 0.4 mm
AJF00738
9JF00916
5. Insert upper hinge pin (16) and lower hinge pin

(13) to the end. 8. Insert selected shim (17) between upper hinge
a Do not insert the shim for the upper hinge pin (16) and rear frame and tighten the 4
pin. mounting bolts.
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
AJF00749
AJF00735
6. Tighten mounting nut (15) of upper hinge pin

(16).
3 Mounting nut:
9. Install lock bolt (12) of lower hinge pin (13).
3 Lock bolt:
510.0 – 607.6 Nm {52.0 – 62.0 kgm}
98 – 123 Nm {10.0 – 12.5 kgm}
AJF00735
WA200-6 9

again.
fuel, coolant and lubricants"):
Only necessary quantity

and lubricants")
10 WA200-6
Removal and installation of 5. Open the engine left side cover and disconnect
counterweight assembly 1 wiring harness connector CN-BR1 (8).
Removal
stop the engine, apply the parking brake, AJF00929
1. Disconnect battery (–) terminal (1) from the

right side and then disconnect battery terminal
(2).
2. Disconnect wiring harness connectors CN-R23

(3) and CN-R24 (4). 6. Open the radiator grille and sling it.
7. Disconnect right and left damper gas cylinders

(9).
AJF00929
AJF00929
3. Disconnect battery terminals (5) and (6) from

the left side.
4. Disconnect wiring harness connector CN-R22 8. Remove the 4 mounting bolts and lift off radia-
(7). tor grille (10).
AJF00930 AJF00929
WA200-6 11
9. Remove wiring harness cover (11). Installation

10. Remove radiator grille lock bracket (12). removal.
[*1]
3 Mounting bolt:
785 – 980 Nm {80 – 100 kgm}
AJF00931
12. Remove wiring harness pipe (14).
AJF00931
13. Sling counterweight (15), remove the mounting

bolts, and lift off the counterweight. [*1]
a When removing the counterweight, insert
bar [1] in its rear part to balance it.
4 Counterweight and batteries (right and
left) assembly: 1,250 kg
AJF00931
12 WA200-6
WA200-6 13
SEN03790-00

© 2007 KOMATSU
All Rights Reserved
14
SEN03791-00
WA200-6
WA200-6 70001 and up

Hydraulic system
Removal and installation of HST pump and 4-gear pump assembly .............................................................. 2
Disassembly and assembly of HST pump assembly ...................................................................................... 6
Removal and installation of HST motor 1 assembly ..................................................................................... 33
Removal and installation of HST motor 2 assembly ..................................................................................... 35
Disassembly and assembly of HST motor assembly.................................................................................... 37
Removal and installation of work equipment control valve assembly ........................................................... 53
Removal and installation of hydraulic tank.................................................................................................... 55
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 57
WA200-6 1
Removal and installation of HST 4. Remove rubber (1).

pump and 4-gear pump
assembly 1
Removal
rear frames.
k Operate the work equipment control lever 2 –
3 times to release the residual pressure in
the work equipment circuit.
terminal of the battery. 5. Disconnect wiring harness connector CN-T01
(2).
k Collect refrigerant (R134a) beforehand.
a Ask professional traders for collecting and
filling the refrigerant (R134a).
the atmosphere.
the refrigerant. Collecting and filling
person.
high, you may scald yourself with the 6. Disconnect the following tubes and hoses.
hot coolant when disconnecting the q (3): HST pump G port hose
heater hoses and draining the cool- q (4): HST pump T2 port hose
ant. Wait until the coolant is cooled, q (5): Hose between HST pump Y port and
and then drain the coolant. steering pump
q (6): Hose between accumulator charge valve
1. Recover the refrigerant (R134a). [*1] A port and fan motor
q (7): Brake valve return hose
6 Radiator: 17 l
3. Remove the operator's cab and floor frame

assembly. For details, see "Removal and
assembly".
2 WA200-6
q (8): Transfer lubricating oil pump suction hose q (16): 4 HST pump discharge hoses
q (9): Work equipment pump suction hose q (17): Hydraulic tank return hose [*3]
q (10): Work equipment pump suction hose q (18): HST pump Fa port hose
q (11): Clutch solenoid valve return hose q (19): HST pump Fa port hose
q (12): Steering pump suction tube [*2]
q (13): Steering pump hose
q (20): Work equipment pump discharge hose
q (14): Transfer lubrication hose

q (15): Brake and fan pump discharge hose
q (21): HST pump A port discharge tube

q (22): HST pump B port discharge tube
WA200-6 3
7. Sling HST pump and 4-gear pump assembly Installation

(23). q Carry out installation in the reverse order to
removal.
8. Remove mounting bolts (24) and (25). [*4]
Mounting bolt M12 (24): 4 pieces [*1]
Mounting bolt M16 (25): 2 pieces a When installing the hoses of the air conditioner
not enter them.
a When installing each air conditioner hose,
check that O-ring (70) is fitted to it.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PG
(equivalent to PAG46)) to O-ring (70).
3 Threaded part of hose (M16 × 1.5):
12 – 15 Nm {1.2 – 1.5 kgm}
20 – 25 Nm {2.0 – 2.5 kgm}
9. Lift off HST pump and 4-gear pump assembly 30 – 35 Nm {3.0 – 3.5 kgm}
(23).
a Since only 1 hanging eye is installed on
the flange side of the pump housing, bal-
ance the slung assembly with your hands.
4 HST pump and 4-gear pump assembly:
110 kg

ant (R134a).
[*2]
2 Hose insertion area of steering pump suction
tube (12): Gasket sealant (THREEBOND
1206E or equivalent)
3 Hose clamp of steering pump suction tube
(12): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
2 Insertion area of hydraulic tank return hose
(17): Gasket sealant (THREEBOND 1206E
or equivalent)
3 Clamp of hydraulic tank return hose (17):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
4 WA200-6
[*4] q Refilling with coolant

2 Mating face of HST pump and 4-gear pump Add coolant through the coolant filler to the
assembly: Gasket sealant (LG-6) specified level. Run the engine to circulate the
3 HST pump and 4-gear pump assembly coolant through the system. Then, check the
mounting bolts: coolant level again.
5
M12 (24) (4 pieces):
98 – 123 Nm {10.0 – 12.5 kgm}
M16 (25) (2 pieces):
and lubricants")
245 – 309 Nm {25.0 – 31.5 kgm}
1. If boss (26) was removed from the HST pump

assembly, install it according to the following
procedure.
a Install boss (26) so that it will be flush with
the shaft end face of pump shaft (27).
q Level difference between boss and pump
shaft end face: Max. 0.5 mm
2. Tighten hexagon socket head bolt (28) of boss

(26).
3 Mounting bolt (28): 86 Nm {8.8 kgm}

again.
WA200-6 5
Disassembly and assembly of 2. Low pressure relief valve assembly

HST pump assembly 1 1) Remove low pressure relief valve assem-
bly (2).
Special tools a Do not change adjustment screw.
New/Remodel
Necessity
Sketch
Q'ty
1 790-201-2720 Push tool q 1

790-201-2150 Push tool t 1
S 2
790-201-2830 Push tool t 1
3 790-201-2740 Push tool q 1
Disassembly
a If the pump body is disassembled, the assem-
bly special tool will be required. See "Assem- 2) Disassemble the low pressure relief valve
bly 3. 5)". according to the following procedure, if
a General view necessary.
a Before loosening the adjustment
screw, check the adjustment dimen-
sion.
1] Remove spring (3) and spring seat
(4).
2] Remove piston (5).
3] Remove locknut (6).
4] Remove adjustment screw (7) from
holder (8).
1. High pressure relief valve assembly

Remove 2 high pressure relief valve assem-
blies (1).
a Do not change adjustment screw.
a Control: O-ring and housing.
a Do not disassemble the high pressure
relief valve assemblies, except the O-rings
and backup rings.
6 WA200-6
3. High pressure cut-off valve assembly

1) Remove high pressure cut-off valve
assembly (9).
a Unscrew setting cartridge completely.
a Control: O-ring and housing.
2) Disassemble the high pressure cut-off

valve according to the following proce-
dure, if necessary.
a Before loosening the adjustment
screw, check the adjustment dimen-
sion.
1] Remove spring seat (10) and spring
(11) from the pump case.
2] Remove barrel assembly (12) from 4. Speed-related valve (DA valve) assembly
the pump case. Remove speed-related valve assembly (19).
3] Remove spring seat (13) and shuttle
spool (15) from barrel (12).
4] Remove spool (16) and piston (17)
from barrel (12).
5] Screw a bolt of M3 × 140 or longer
one and pull valve seat (14) out of the
pump case.
6] Remove locknut (18), and then
remove adjustment screw (97) from
holder (98).
WA200-6 7
5. Directional solenoid valve (34) 3) Disassemble valve housing assembly (35)

1) Remove directional solenoid valve assem- according to the following procedure.
bly (34). 1] Remove 2 springs (37) and 2 collars
(38).
2] Remove piston (39).
a Do not remove 4 plugs (41) and plug
(42) from housing.
2) Remove 2 solenoid valves (36) from direc-

tional solenoid valve assembly (34).
a Remove cap (36B) by turning it and
remove coil (36A) by pulling it from
the solenoid valve, and then remove
the tube from valve housing assembly
(35).
8 WA200-6
6. Charge pump assembly (44) 3) Mark position of the port plate, (m1).
1) Remove 4 mounting bolts (97) and charge 4) Loosen port plate fixation.
pump assembly (44).
2) Remove wear plate (43).
3) Remove gear (46).
4) Remove coupling (48) and key (49).
a Do not remove bearing metal (47) from
flange (45).
5) Lift off port plate assembly (51) and con-

trol plate (52).
8. Cylinder block and piston assembly (54)

1) Press cylinder (53) to the bottom.
2) Remove fixing indexing screw (50).
7. Port plate assembly (51)
1) Mark the position (angle) of indexing
screw (50), (m0).
a Record setting measure (angle).
2) Set indexing screw to disassembly posi-
tion (a). (0 degree)
WA200-6 9
3) Remove cylinder block and piston assem-

bly (54).
4) Disassemble cylinder block and piston

assembly (54) according to the following
procedure.
10 WA200-6
1] Remove the assembly of pistons (57) 5] Remove snap ring (63) from the cylin-
and retainer (58) from cylinder block der block.
(56). k Snap ring (63) will jump out.
2] Remove 9 pistons (57) from retainer Take care.
(58). 6] Remove spring (62) and 2 shims (65).
a Check of pistons
q Check that there are no scratches or
metal deposits on sliding surface (b),
and there is no axial play (c), (other-
wise, pistons must be replaced in
sets).
3] Remove retainer guide (59) from cyl-

inder block (56).
4] Remove shim (60) and spring (61).
a When any of cylinder block (56), control

plate (52), retainer guide (59), retainer
(58), and shim (60) needs to be replaced,
replace the whole cylinder block since a a Check of cylinder block and control plate.
dimension of shim (60) must be adjusted. q Cylinder bores (d), splines (e).
WA200-6 11
q Cylinder surface ( f ) free of scoring. 5) Remove snap ring (69).

q Control plate (g) without scoring.
a Fit faces (f) and (g) (having notch (B) on
the ellipse) together.
10. Drive shaft assembly

1) Remove drive shaft assembly (66) with
plastic hammer strokes.
9. Seal
1) Protect drive shaft (66) with a tape etc.
2) Disassemble the drive shaft assembly

1] Remove snap ring (70).
3) Tighten screws [1] into the holes of shaft 2] Remove bearing (71) from drive shaft
seal (68) blocked with rubber. (72).
4) Pull out shaft seal (68) with pliers. a Check of drive shaft
q Splines for damage or fretting
q Running surfaces
q Groove cut by shaft seal
12 WA200-6
11. Swivel cradle (73) and bearing cups (74) q Bearing surfaces (j) of cradle (76)
1) Remove swivel cradle (73).
2) Remove bearing cups (74).
a Check
q Bearing cups set
4) Remove lever (75) from cradle (73).

a Check of cradle lever (75)
3) Remove wire (95), articulate pin (96) and

bearing (74b) from swivel cradle (73).
12. Servo cylinder assembly

1) Remove plugs (77).
2) Remove joint pins (78).
3) Mark positions (m2) and (m3) of the cov-
a Check of cradle (76) ers (80) and (81), note measure of "zero
q Sliding surface (h) free from position" (k).
scoring 4) Loosen nut (79).
WA200-6 13
7) Remove servo piston assembly (82).

a Check of groove (A)
5) Remove covers (80) and (81).
8) Disassemble servo piston assembly (82)

a Disassemble either side first, then
disassemble the other side.
1] Using tool S1, push collar (83).
2] Break and remove plastic cap (86).
(Prepare new one for assembly.)
3] Remove ring (84).
4] Remove snap ring (85).
6) Remove O-rings (101) from both sides.
5] Remove collar (83).

6] Remove large spring (87) and small
spring (88).
7] Remove collar (89).
14 WA200-6
8] Disassemble the opposite side simi- Assembly

larly. a Clean all the parts and remove burrs, etc.
9] Remove rod (91) from piston (90). a Coat the rotary parts and sliding parts with
a When any of rod (91), collar (83), engine oil (for details, see "Table of fuel, cool-
snap ring (85), piston (90), and ant and lubricants") before installing.
ring (84) needs to be replaced, a If the tightening torque of a mounting bolt, nut,
replace all of the servo piston or plug is not shown in this manual, see the
assembly (82) since a dimension tightening torque table.
of ring (84) must be adjusted.
1. Pump case
1) Install guide ring (92).
13. Pump case

1) Remove guide ring (92) from servo cylin-
der mounting part (100) of pump case. 2) Install O-ring (94).
2) Remove seal ring (93) and O-ring (94).
WA200-6 15
3) Install seal ring (93) over O-ring (94). a Assemble either side first, then assemble
a The deformation of the seal has to be the other side.
done with care so as not to damage 2] Install collar (89).
the sealing edges. 3] Install small spring (88) and large
a Check the position of seal ring (93). If spring (87).
necessary, straighten it using a finger. 4] Install collar (83).
2. Servo piston assembly (82) 5] Using tool S1, push collar (83).
a Assemble the servo piston assembly in an 6] Install snap ring (85).
oil pan. 7] Install ring (84).
1) Dip piston (90), rod (91), springs (87) and 8] Install new plastic cap (86).
(88), collars (83) and (89) in engine oil (for 9] Turn over upside down.
details, see "Table of fuel, coolant and 10] Assemble the opposite side similarly.
lubricants").
2) Assemble the servo piston assembly
1] Install rod (91) to piston (90).
3) Insert guide pin [4] into servo piston

assembly (82).
4) Grease slightly guide pin [4].
5) Install servo piston assembly (82) with
guide pin [4].
16 WA200-6
a When any of rod (91), collar (83), 3) Insert completely swivel cradle (73) into
snap ring (85), piston (90), and ring housing.
(84) needs to be replaced, replace all a Assistance: Devices, e.g. clamp, rub-
of the servo piston assembly (82) ber rings, grease and string
since a dimension of ring (84) must a Pay attention for correct seat of the
be adjusted. swivel cradle (73) in the housing.
3. Cradle and bearing cups

1) Insert bearing cup set (74a).
a Fit hole (c) of cup set (74a) to the pin in
the case.
a Install so that servo piston (82) and

lever (75) will be as shown below.
2) Swivel cradle (73)

Assemble bearing (74b), wire (95), lever
(75) and articulating pin (96) to cradle
(76).
k Remove auxiliary device.
a Completed cradle holding device
WA200-6 17
a Check: Location of the swivel-bearing 6) Hold swivel (73) in position utilizing the
in the bearing seat screw.
q Centralize swivel (73) by using a k Do not use force.
measuring device (dial gauge or 7) Install second holding device [6] diago-
depth measurement [5]). nally and fix swivel (73).
q The measured values at the 2 points
of (P1) and (P2) in the following figure
must be the same.
4) Fit joint pin (78) and plug (77).

a Pinch wire (95) in pin (78).
5) Make holding devices [6] (2 pieces).

a Holding device [6] "swivel cradle"
18 WA200-6
4. Drive shaft assembly a Before setting seal (68), perform the fol-
a Install the bearing to the shaft in the cor- lowing procedures.
rect direction. 6) Measure depth (d1) to the groove bottom
1) Install the ring to the shaft first, and then of snap ring (67).
install the bearing to the shaft. 7) Make a mark of the insertion depth of
2) Using tool S2, press fit bearing (71) to push tool S3 (finishing position) (m4 = d1)
drive shaft (72). on push tool S3.
8) Using tool S3, press fit seal (68).
a Threads of shaft: M16, Thread depth: 36
mm

4) Install drive shaft assembly (66).

WA200-6 19
5. Cylinder block and piston assembly

1) Assemble the cylinder block and piston
assembly according to the following pro-
cedure.
20 WA200-6
1] Install 2 shims (65) and spring (62) to 5] Install 9 pistons (57) to retainer (58).
the cylinder block. 6] Install piston and retainer assembly to
2] Compress spring (62) and install snap cylinder block (56).
ring (63). a Apply oil to piston and piston pad.
3] Install springs (61) and shim (60) to
cylinder block (56).
a When any of cylinder block (56), con-
trol plate (52), retainer guide (59),
retainer (58), and shim (60) needs to
be replaced, replace the whole cylin-
der block since a dimension of shim
(60) must be adjusted.
4] Install retainer guide (59).
2) Remove holding device [6].

a Fit cylinder completely with pistons
and retaining device.
3) Assembly aid:
Hold cylinder block and piston assembly
(54) by using O-ring (96).
WA200-6 21
6. Control plate (52) 1) Press cylinder block (56) to the bottom.

a Control plate clockwise rotation – indexed 2) Screw in indexing screw (50).
in the direction of rotation. a Groove in mounting position.
a Noise grooves are machined – in based (The groove is directed up in the fol-
on the direction of rotation. lowing figure.)
a Notch (B) is seen on one side.
3) Insert control plate (52) – clockwise rota-

a Indexing screw basic setting – indexing tion.
screw (50) (The end is eccentric.) a Insert the control plate so that notch (B)
Dimension (m): 29 ± 0.75 mm will not be seen.
22 WA200-6
7. Port plate (51) 9. Charge pump assembly (44)

1) Assemble port plate (51), matching (m1). 1) Install wear plate (43).
k Spring preloaded! 2) Install coupling (48) and key (49).
2) Insert port plate assembly (51) into hous- a Bearing metal (47) is already in the
ing, guided with 2 guide bolts [1] that flange (45).
screwed opposite angle. 3) Install gear (46) to flange (45).
4) Install charge pump assembly (44) with 4
mounting bolts (97).
3) Locking screw (50) – observe adjusting

measure, the angle (m0).
8. Servo piston cover

Install servo piston covers (80) and (81) to both
sides of match mark positions (m2) and (m3).
a Cover (80) will be removed because of fill-
ing oil.
WA200-6 23
10. Directional solenoid valve (34) 2) Install 2 solenoid valves (36) to valve
1) Assemble valve housing assembly (35) housing assembly (35).
according to the following procedure. a Fit the tube to the solenoid valve
1] Install plug (42) to housing. housing and install coil (36A) and cap
2 Threads of plug: (36B).
ThreeBond No. 1305 or equivalent
2] Install 4 plugs (41).
3 Plug: 5.6 Nm {0.57 kgm}
3] Install piston (39).
4] Install 2 collars (38) and 2 springs
(37).
3) Install directional solenoid valve assembly

(34).
3 Plug: 9.8 Nm {1 kgm}
24 WA200-6
11. Speed-related valve (DA valve)

Fit the O-ring and install speed-related valve
assembly (19).
12. High pressure cut-off valve assembly

1) Assemble the high pressure cut-off valve
assembly according to the following pro-
cedure.
1] Install adjustment screw (97) and
locknut (18) to holder (98).
2] Install piston (17) and spool (16) to
barrel (12).
3] Install shuttle spool (15), valve seat
(14), and spring seat (13) to barrel
(12). 2) Fit the O-ring and install high pressure
4] Install barrel assembly (12) to the cut-off valve assembly (9).
pump case. a After installing the pump assembly to
5] Install spring (11) and spring seat (10) the machine, adjust the high pressure
to the pump case. cut-off valve assembly. For details,
a Set the spring to the dimension mea- see Testing and adjusting, "Testing
sured before disassembly. and adjusting HST oil pressure".
WA200-6 25
13. Low pressure relief valve assembly 14. High pressure relief valve assembly
1) Assemble the low pressure relief valve Fit the O-ring and install 2 high pressure relief
assembly according to the following pro- valve assemblies (1).
cedure. 3 High pressure relief valve assembly:
1] Install adjustment screw (7) to holder 200 ± 10 Nm {20.39 ± 1.02 kgm}
(8).
2] Install locknut (6).
3] Install piston (5).
4] Install spring seat (4) and spring (3) to
the pump case.
15. Filling with oil

a Remove servo piston cover (80).
(See next item.)
Fill up hydraulic aggregates with medium
before start-up.
2) Fit the O-ring and install low pressure

relief valve assembly (2).
3 Low pressure relief valve assem-
bly: 70 Nm {7.14 kgm}
26 WA200-6
16. Servo piston cover (80) 17. Before starting

1) Install servo piston cover (80) to match a Observe the operating instructions before
mark position (m3). starting.
2) Adjust zero position according to mea- q Check the machine for remarkable faults.
sure, (k). q Do not operate the machine with defective
k Adjustments of the correct zero instruments, warning lights or control ele-
position are to be carried out after ments.
installation into the machine or on q All safety devices must be in a secure
the bench test. position.
q Do not carry with you movable objects or
secure them to the machine.
q Keep oily and inflammable material away
from the machine.
q Before entering the operator’s cab, check
if persons or obstacles are beside or
beneath the machine.
q Be careful when entering the operator’s
cab, use stairs and handles.
q Adjust your seat before starting.
WA200-6 27
18. Tightening torque table

a If the tightening torque of a mounting bolt,
nut, or plug is not shown in this manual,
tighten that part according to the following
tightening torque table.
1) Bolts
The values stated are valid for bolts with
metric ISO threads to DIN 13 part 13, as
well as head areas to DIN 912 socked
head cap screws, DIN 913 hexagon bolt
or DIN 933 hexagon bolts with threads up
to the head.
Tensile strength class
Thread 8.8 10.9 12.9
Nm kgm Nm kgm Nm kgm
M3 1.1 0.11 1.6 0.16 1.9 0.19
M4 3.1 0.32 4.5 0.46 5.3 0.54
M5 6.1 0.62 8.9 0.91 10.4 1.06
M6 10.4 1.06 15.5 1.58 18 1.84
M8 25 2.55 37 3.77 43 4.38
M10 51 5.20 75 7.65 87 8.87
M12 87 8.87 130 13.26 150 15.30
M14 140 14.28 205 20.90 240 24.47
M16 215 21.92 310 31.61 370 37.73
M18 300 30.59 430 43.85 510 52.01
M20 430 43.85 620 63.22 720 73.42
M22 580 59.14 830 84.64 970 98.91
M24 740 75.46 1060 108.09 1240 126.44
28 WA200-6
2) Plugs
1] Plugs with internal hexagon and pro-
file seal ring
Tightening torque Tightening torque

Thread Thread
Nm kgm Nm kgm
M8 x 1 5 0.51 G 1/8 A 10 1.02
M10 x 1 10 1.02 G 1/4 A 30 3.06
M12 x 1.5 20 2.04 G 3/8 A 35 3.57
M14 x 1.5 30 3.06 G 1/2 A 60 6.12
M16 x 1.5 35 3.57 G 3/4 A 90 9.18
M18 x 1.5 40 4.08 G1A 140 14.28
M20 x 1.5 50 5.10 G 11/4 A 240 24.47
M22 x 1.5 60 6.12 G 11/2 A 300 30.59
M26 x 1.5 70 7.14
M27 x 2 90 9.18
M30 x 1.5 100 10.20
M33 x 2 140 14.28
M42 x 2 240 24.47
M48 x 2 300 30.59
WA200-6 29
2] Plugs with internal hexagon, O-ring

and UNF-, UN- threads to SAE J 514
Tightening torque Tightening torque

Thread Thread
Nm kgm Nm kgm
7/16-20UNF 15 1.53 M12 x 1.5 20 2.04
1/2-20UNF 20 2.04 M14 x 1.5 30 3.06
9/16-18UNF 25 2.55 M27 x 1.5 90 9.18
3/4-16UNF 72 7.34
7/8-14UN 127 12.95
11/16-12UN 147 14.99
13/16-12UN 173 17.64
15/16-12UN 198 20.19
15/8-12UN 320 32.63
17/8-12UN 390 39.77
30 WA200-6
3) SEAL-LOCK - sealing nuts
Tightening torque
Thread
Nm kgm
M6 10 1.02
M6 x 0.5 11 1.12
M8 22 2.24
M8 x 1 24 2.45
M10 40 4.08
M10 x 1 44 4.49
M12 69 7.04
M12 x 1.5 72 7.34
M14 110 11.22
M14 x 1.5 120 12.24
M16 170 17.34
M16 x 1.5 180 18.35
WA200-6 31
4) Oval head screw

Oval head screw with inner TORX, thread
precoated with "Precote 80"
Tensile strength class
10.9 11.9
Thread
Tightening torque
Nm kgm Nm kgm
M3 2.1 0.21 — —
M4 4.7 0.48 — —
M5 9.1 0.93 9.5 0.97
M6 15.8 1.61 — —
M8 37.7 3.84 — —
32 WA200-6
Removal and installation of HST 4. Disconnect front drive shaft (1) from the trans-
motor 1 assembly 1 fer. [*2]
Removal
rear frames.
k Operate the work equipment control lever 2
– 3 times to release the residual pressure in
k Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
k Disconnect the cable from the negative (–) 5. Disconnect the following wiring harness con-
terminal of the battery. nectors from the top of HST motor 1.
q (2): CN-T06
q Precautions for handling refrigerant q (3): CN-T11
the atmosphere.
person.
hot coolant when disconnecting the 6. Disconnect the following hoses from HST
heater hoses and draining the cool- motor 1.
ant. Wait until the coolant is cooled, q (4): T1 port hose
and then drain the coolant. q (5): T2 port hose
q (6): A port hose
1. Recover the refrigerant (R134a). [*1] q (7): B port hose

6 Radiator: 17 l

assembly".
WA200-6 33
7. Using wire [1], sling HST motor 1 assembly (8).
8. Remove the 4 HST motor 1 mounting bolts.

[*3]
9. Using wire [1], lift off HST motor 1 assembly

(8).
4 HST motor 1 assembly: 35 kg

ant (R134a).
[*2]
3 Drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 HST motor 1 assembly mounting bolt:
Installation 98 – 123 Nm {10.0 – 12.5 kgm}
removal. q Refilling with oil (Hydraulic tank)
[*1] level. Run the engine to circulate the oil
a When installing the hoses of the air conditioner through the system. Then, check the oil level
circuit, take care that dirt, dust, water, etc. will again.
not enter them.
check that O-ring (70) is fitted to it. fuel, coolant and lubricants"):
a Check O-ring (70) for a flaw and deterioration. Only necessary quantity
compressor oil for new refrigerant (R134a) q Refilling with coolant
(DENSO: ND-OIL8 or ZEXEL ZXL100PG Add coolant through the coolant filler to the
(equivalent to PAG46)) to O-ring (70). specified level. Run the engine to circulate the
3 Threaded part of hose (M16 × 1.5): coolant through the system. Then, check the
12 – 15 Nm {1.2 – 1.5 kgm} coolant level again.
20 – 25 Nm {2.0 – 2.5 kgm}
30 – 35 Nm {3.0 – 3.5 kgm} and lubricants")
34 WA200-6
Removal and installation of HST 4. Disconnect front drive shaft (1) from the trans-
motor 2 assembly 1 fer. [*2]
Removal
rear frames.
k Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
k Disconnect the cable from the negative (–) 5. Disconnect the following wiring harness con-
terminal of the battery. nectors from the top of HST motor 1.
q (2): CN-T07
q Precautions for handling refrigerant q (3): CN-T10
the atmosphere.
person.
hot coolant when disconnecting the 6. Disconnect the following hoses from HST
heater hoses and draining the cool- motor 2.
ant. Wait until the coolant is cooled, q (4): T1 port hose
and then drain the coolant. q (5): T2 port hose
q (6): A port hose
1. Recover the refrigerant (R134a). [*1] q (7): B port hose

6 Radiator: 17 l

assembly".
WA200-6 35
7. Using wire [1], sling HST motor 2 assembly (8).
8. Remove the 4 HST motor 2 mounting bolts.

[*3]
9. Using wire [1], lift off HST motor 2 assembly

(8).
4 HST motor 2 assembly: 35 kg

ant (R134a).
[*2]
3 Drive shaft mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*3]
3 HST motor 2 assembly mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
Installation
q Carry out installation in the reverse order to q Refilling with oil (Hydraulic tank)
removal. Add oil through the oil filler to the specified
[*1] through the system. Then, check the oil level
a When installing the hoses of the air conditioner again.
not enter them.
a When installing each air conditioner hose, fuel, coolant and lubricants"):
check that O-ring (70) is fitted to it. Only necessary quantity
a When connecting each refrigerant pipe, apply q Refilling with coolant
compressor oil for new refrigerant (R134a) Add coolant through the coolant filler to the
(DENSO: ND-OIL8 or ZEXEL ZXL100PG specified level. Run the engine to circulate the
(equivalent to PAG46)) to O-ring (70). coolant through the system. Then, check the
3 Threaded part of hose (M16 × 1.5): coolant level again.
12 – 15 Nm {1.2 – 1.5 kgm}
5
20 – 25 Nm {2.0 – 2.5 kgm} (For details, see "Table of fuel, coolant
and lubricants")
30 – 35 Nm {3.0 – 3.5 kgm}
36 WA200-6
Disassembly and assembly of 2. EP servo valve assembly and cover (HST

HST motor assembly 1 motor 1)
Special tools
New/Remodel
Necessity
Sketch
Q'ty
CJW12101
4 02010-20783 Bolt q 1
790-201-2740 Push tool t 1
S
5 793T-417-1120 Push tool q 1
02010-20783 Bolt q 1
Disassembly
1. Seal
2) Remove snap ring (2) and shim (3).
CJW11980
1) Remove 4 mounting bolts and solenoid

valve and housing assembly (5).
a Take care of the spring which may
jump out.
3) Tighten screws [1] into the holes of shaft

seal (4) blocked with rubber.
4) Pull out shaft seal (4) with pliers.
CJW11982
CJW11981
WA200-6 37
2) Remove spring seat (7) and spring (8) 6) Cover

from port plate (6). 1] Remove cover (25).
3) Remove spring seat (9) and spring (12). 2] Remove plug (26) from cover (25).
4) Remove spring seat (11) and spring (10).
CJW11987
CJW11983
3. HA servo valve and directional shuttle valve

5) Disassemble the solenoid and housing assembly and flushing valve assembly (HST
assembly (5). motor 2)
1] Remove caps (14), coil (15) and snap
ring (16) of the solenoid in order.
CJW12104
CJW12163
2] Remove spool (18) and bushing (19)

from housing (13).
3] Remove pin (20).
a Do not remove nut (21) and screw
(22).
4] Remove plugs (24) from housing
(13).
a Do not remove plug (23).
CJW12103
38 WA200-6
1) Remove the 4 mounting bolts and sole- 4) Disassemble 2 solenoids and housing
noid valve and housing assembly (27) assembly (27).
from port plate (6). 1] Remove caps (36) and (37), coils (38)
a Take care of the spring which may and (39), and bushing (40) of the
jump out. solenoid in order.
CJW12105 CJW12106
2) Remove spring seat (29) and spring (30)

from port plate (6).
3) Remove spring seat (31) and spring (34).
CJW12125
a Disassemble the housing assembly

2] Remove snap ring (43), control bush-
ing (44), and control piston (45) from
housing (35).
3] Remove pin (46).
a Do not remove nut (47) and screw
(48).
CJW12108
WA200-6 39
4] Remove control piston (49) and

spring (50) from housing (35).
5] Remove plug (51).
a Do not remove 5 plugs (52).
CJW12107
5) Remove flushing valve assembly (53)

from port plate (6).
CJW12112
40 WA200-6
6) Disassemble flushing valve assembly (53)

2] Remove spring (55), plunger (56), ori-
fice (57), and snap ring (58).
3] Remove 2 plugs (59).
4] Remove spring (60), spring seat (61),
and spool (62).
6] Remove guide (64), orifice (65), and
guide (66).
CJW12164
WA200-6 41
4. Preparation of removal of port plate assem-

bly (6)
(Common to HST motors 1 and 2)
1) Break and remove plastic cap (71) and
check installed dimension (a) of Minimum
Flow Rate Adjustment screw (67).
CJW12111
CJW12165
6) Insert screw [6] to Maximum Flow Rate

Adjustment screw and fix rotary group
(70).
Screw [6]: M12 × 100 mm or longer.
2) Loosen locknut (68) and remove Minimum

3) Push piston (69) to set the angle of rotary
group (70) to 0°.
4) Break and remove plastic cap (71) and CJW12126
check installed dimension (b) of Maximum
5) Remove Maximum Flow Rate Adjustment
screw (96).
a Plastic cap (71) is used to prevent
rusting. Since a spare for it is not
supplied, apply paint or take another
rust-preventive measure after assem-
bling.
42 WA200-6
7) Make match marks (c) between port plate a Check of port plate
(6) and housing (82). q Sliding surface and side guides free
8) Remove port plate assembly (6). of scoring and no wear
CJW12115 CJW12002
5. Disassemble port plate assembly (6) according a Check of control plate

to the following procedure. Faces smooth and even, free of cracks
1) Remove control lens (80). and scoring
2) Remove bolt (73) and piston (74).
a Do not remove screw (76), rod (72), and
piston (69).
CJW12039
CJW12113
6. Removal of shaft and rotary group assem-

bly (81)
1) Remove O-ring (75).
3) Screw a bolt of M4 and pull out valve 2) Screw [2] in threaded pin into center pin
guide (77). (d).
4) Remove poppet (78). a Fix the cylinder with disc and locknut.
5) Remove valve seat (79). q Screw size: M6 × 92 mm
3) Remove screw [6].
CJW12119
CJW12127
WA200-6 43
4) Push the shaft end with a press to remove a Check of housing

shaft and rotary group assembly (81) from q Sliding surface and slide guides
housing (82). free of scoring and no wear
k If the bearings are used again, do
not hit on the drive shaft.
a Since shaft and bearing are used as

an assembly, do not remove the bear-
a If a press is not available, push the shaft ing.
end with tool [3] or [4] to remove rotary
group assembly (81). 7. Disassembly of rotary group assembly (70)
2) Remove cylinder block (83).
3) Remove shim (84) from cylinder block

(83).
44 WA200-6
a Check of cylinder block (83) a Check of piston and center pin

q Bores free of scoring, no evi- q No scoring and no pittings
dence of wear
CJW12014
a Do not disassemble drive shaft and bear-

4) Remove retaining ring assembly (85). ing assembly (89). (If the drive shaft and
a Screws are glued. Warm it up to max. bearing assembly is defective, replace it
120°C and remove with Torx-tools. whole.)
5) Remove 7 pistons (86), spring (87), and
center pin (88) from shaft and bearing
assembly (89).
a Check of retaining ring (85)

q No scoring and no evidence of
wear
WA200-6 45
Assembly 4) Insert the piston to the end of cylinder

a Clean all the parts and remove burrs, etc. block (83) and secure it with screw [2].
a Coat the rotary parts and sliding parts with
engine oil (for details, see "Table of fuel, cool-
ant and lubricants") before installing.
a If the tightening torque of a mounting bolt, nut,
or plug is not shown in this manual, see the
tightening torque table.
CJW12022
1. Assembly of rotary group assembly (70)
a If the drive shaft and bearing assembly
(89) is defective, replace it whole. (The
parts of this assembly cannot be supplied
loose.)
1) Install 7 pistons (86), center pin (88), and
spring (87) to the drive shaft and bearing
assembly (89). 5) Set bolt S4 to shaft and rotary group
2) Install retaining ring assembly (85) with assembly (81) and protect the drive shaft
the screw. by type.
a For the tightening torque of the screw, a Threads of shaft: 7/16-14UNC-2B,
see "Tightening torque table". Thread depth: 28 mm
CJW12128 CJW12169
3) Insert shim (84), center pin (88), and pis- 2. Installation of rotary group assembly
ton (86) in cylinder block (83). 1) Heat housing (82) to 80°C.
a Make sure all parts are fitted in cor-
rectly.
CJW12024
CJW12021
46 WA200-6
2) Insert shaft and rotary group assembly 3. Port plate assembly (6)
(81) into housing (82) to seat position. 1) Assemble port plate assembly (6) accord-
ing to the following procedure.
1] Install valve seat (79).
2] Install poppet (78).
3] Install valve guide (77).
CJW12117
CJW12119
3) Insert screw [6] (M12 × 100 mm or

longer). (Fix the tapered part of cylinder
block (83) and set the angle to 0°.)
5) Install O-ring (75) to the housing. a Piston (69), rod (72), and screw (76)
are already in the port plate (6).
4] Install piston (74) and bolt (73).
5] Thinly apply grease to control plate
(80), and then install it to the sliding
surface of the port plate assembly (6).
CJW12118
CJW12113
WA200-6 47
a Take care of assembly design!

2) Install port plate assembly (6) to housing
(82), matching marks (c) made when it
was removed.
CJW12122
CJW12115
4. Installation of Minimum Flow Rate Adjust-

ment screw (67) and Maximum Flow Rate
Adjustment screw (96).
1) Remove screw [6] and set Maximum Flow
Rate Adjustment screw (96).
Dimension (b) is the value measured at
the time of disassembly.
a When bolt is changed,
q Since the bolt is used to plug the
hole simply, do not replace it with
long one.
2) Swivel rotary group (70) to "starting posi-
tion".
3) Set Minimum Flow Rate Adjustment screw
(67) to dimension (a).
a Dimension (a) is important for all the
type.
a Tighten fixing screws (67) and (96)
with torque.
48 WA200-6
5. HA servo valve and directional shuttle 3] Install spool (62), spring seat (61),
valve assembly and flushing valve assem- and spring (60).
bly (53) (HST motor 2) 4] Install 2 plugs (59).
1) Assemble the flushing valve assembly 3 Plug: 40 Nm {4.1 kgm}
according to the following procedure. 5] Install snap ring (58), orifice (57),
1] Install guide (66), orifice (65), and plunger (56), and spring (55).
guide (64). 6] Install plug (54).
3 Guide (66): 3 Nm {0.31 kgm} 3 Plug: 50 Nm {5.1 kgm}
3 Guide (64): 8 Nm {0.81 kgm}
2] Install plug (63).
3 Plug:
29 – 38 Nm {2.96 – 3.89 kgm}
CJW12164
WA200-6 49
2) Install flushing valve assembly (53) to port 6] Install 2 solenoids to housing (35).
plate (6). a Install bushing (40), coils (39) and
3 Plug: (38), and caps (37) and (36) of the
55 – 60 Nm {5.61 – 6.12 kgm} solenoid in order.
CJW12112 CJW12106
3) Assemble housing assembly (27) accord-

ing to the following procedure.
1] Install plug (51) to housing (35).
2] Install spring (50) and control piston
(49) to housing (35).
a 5 plugs (52) are already in the hous-
ing (35).
CJW12107 4) Install spring (34) and spring seat (31) to

the port plate.
5) Install spring (30) and spring seat (29).
3] Install pin (46).

4] Install control piston (45) and control
CJW12125
bushing (44).
5] Install snap ring (43).
CJW12108
50 WA200-6
6) Install solenoid valve and housing assem- 2) Assemble housing assembly (5) according
bly (27) with the 4 mounting bolts to port to the following procedure.
plate (6). 1] Install plug (24) to housing (13).
2] Install pin (20).
3] Install bushing (19) and spool (18) to
housing (13).
a Plugs (23) are already in the housing
(13).
CJW12105
CJW12103
6. EP servo valve assembly and cover

(HST motor 1)
1) Cover
1] Install plug (26) to cover (25).
3 Plug:
29 – 38 Nm {3.0 – 3.9 kgm} 4] Install snap ring (16), coil (15), and
2] Install cover (25). cap (14) in order to housing assembly
3 Mounting bolt: (13).
39 – 49 Nm {4.0 – 5.0 kgm}
CJW12102
CJW11987
WA200-6 51
3) Install spring (10) and spring seat (11) to 5) Protect drive shaft (1) with a tape etc.
port plate (6). 6) Install snap ring (2).
CJW11980
CJW11983
8. Filling with oil

Fill up hydraulic aggregates with medium
6) Install solenoid valve and housing assem- before start-up.
bly (5) with the 4 mounting bolts.
CJW12036
CJW11982
9. Tightening torque table

7. Seal (Common to HST motors 1 and 2) a If the tightening torque of a mounting bolt, nut,
1) Before setting seal (4), measure depth (f) or plug is not shown in this manual, see Disas-
to the groove bottom of snap ring (2). sembly and assembly of HST pump assembly,
2) Make a mark of insertion depth (e) of push "Tightening torque table".
tool S5, (f) + thickness of shim (3), on
push tool S5. 10. Before starting
3) Using push tool S5, press fit seal (4). a Observe the operating instructions before
4) Install shim (3). starting.
q Check the machine for remarkable faults.
q Do not operate the machine with defective
instruments, warning lights or control ele-
ments.
q All safety devices must be in a secure
position.
CJW12170 q Do not carry with you movable objects or
secure them to the machine.
q Keep oily and inflammable material away
from the machine.
q Before entering the operator’s cab, check
if persons or obstacles are beside or
beneath the machine.
q Be careful when entering the operator’s
cab, use stairs and handles.
q Adjust your seat before starting.
52 WA200-6
Removal and installation of work 4. Disconnect the following hoses and tubes from
equipment control valve work equipment control valve assembly (2).
[*1]
assembly 1 a Plug the disconnected hoses to prevent oil
Removal leakage.
k Stop the machine on a level ground, apply a Put tags on the disconnected hoses and
the parking brake, and put chocks under record the installed positions etc. on them.
the tires. q (3): P port hose
q (4): P port hose
1. Articulate the machine to the left and raise the q (5): T port hose
lift arm. q (6): T port hose
q (7): A1 port hose
2. Dump the bucket and set stand [1] and hydrau- q (8): B1 port hose
lic jack [2] to support the lift arm and adjust its q (9): A2 port tube
height. q (10): B2 port tube
k Support the lift arm securely.
q (11): Bucket dump PPC hose
k Stop the engine and loosen the hydrau-
q (12): Bucket tilt PPC hose
lic tank cap gradually to release the q (13): Lift arm lower PPC hose
pressure in the tank. q (14): Lift arm raise PPC hose
k Operate the work equipment control
lever 2 – 3 times to release the residual
pressure in the work equipment circuit.
5. Loosen 2 lower bracket mounting bolts (15)

and remove 1 upper bracket mounting bolt
(16).
3. Remove cover (1) on the work equipment con- a Do not remove 2 lower bracket mounting
trol valve. bolts (15) but just loosen them.
6. Remove work equipment control valve assem-

bly (2).
WA200-6 53
Installation
removal.
[*1]
a Connect PPC hoses (11), (12), (13) and (14)
according to their band colors as shown in the
following table.
q Work equipment control lever specification:
Mono-lever
No. Connecting point Band color
(11) Bucket dump Orange
(12) Bucket tilt Red
(13) Lift arm lower Blue
(14) Lift arm raise Yellow

again.
54 WA200-6
Removal and installation of 6. Remove tube (9) between the hydraulic tank
hydraulic tank 1 and hydraulic oil filter.
Removal 7. Remove 2 mounting bolts (10) and bracket and

k Stop the machine on a level ground and set hydraulic oil filter (11).
the lock bar to the frame to fix the front and a Fix the bracket and hydraulic oil filter
rear frames. assembly (11) to the machine with ropes.

a Check that the cover is locked securely.
2. Remove right fender (2).

4 Fender: 25 kg
8. Disconnect suction hose (12) and return hose

(13) from the hydraulic tank tube. [*1]
9. Disconnect hoses (14) and (15) from the block

on the hydraulic tank.
10. Disconnect hoses (16), (17) and (18) from the

block on the hydraulic tank.
a Plug the disconnected hoses to prevent oil
leakage.
a Put tags to the disconnected hoses and
record the installed positions etc. on them.
3. Remove hydraulic tank top cover (3).

k Loosen the hydraulic tank cap gradu-
ally to release the pressure in the
hydraulic tank.
4. Remove ladder (4).
5. Remove covers (5), (6), (7) and (8).
11. Sling the hydraulic tank assembly.
WA200-6 55
12. Remove 2 upper mounting bolts (19) and lower Installation

mounting bolt (20) of the hydraulic tank. [*2] q Carry out installation in the reverse order to
removal.
[*1]
2 Insertion areas of suction hose (10) and
return hose (11): Gasket sealant (THREE-
BOND 1206E or equivalent)
3 Clamps of suction hose (12) and return hose
(13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Upper mounting bolt (19) of hydraulic tank:
98 – 123 Nm {10.0 – 12.5 kgm}

13. Lift off hydraulic tank assembly (21). Add oil through the oil filler to the specified
4 Hydraulic tank and ladder assembly: through the system. Then, check the oil level
160 kg (including hydraulic oil) again.
56 WA200-6
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1
1. Cylinder assembly
Special tools Set cylinder assembly (1) to tool U1.
New/Remodel
2. Cylinder head and piston rod assembly
Necessity
Sketch
1) Using tool U2, remove cylinder head (2)
Q'ty
from the cylinder.
790-502-1003 Repair stand t 1

1
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
790-102-1320 Socket (for lift) t 1 CED00174
790-102-1330 Socket (for bucket)
or commer- (Width across flats t 1
3 cially available 46 mm)
Socket
790-302-1280 (for steering) t 1

790-101-5021 • Grip 1
01010-50816 • Bolt 1 2) Pull cylinder head and piston rod assem-
4
790-201-1791
• Push tool
1
bly (3) out of cylinder (4).
(Lift and bucket) a Since oil will flow out when the piston
U • Push tool rod assembly is pulled out of the cyl-
790-201-1811 1
(Steering) inder, prepare an oil receiver.
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5
• Plate
790-201-1610 1
(Lift and bucket)
790-201-1550 • Plate (Steering) 1
9JF01062
6 790-720-1000 Expander q 1
Ring
796-720-1670 (Lift and bucket) q 1
Clamp
7 07281-01159 (Lift and bucket) q 1
796-720-1740 Ring (Steering) q 1

07281-00809 Clamp (Steering) q 1
WA200-6 57
3. Piston and cylinder head 5. Fine disassembly of cylinder head assem-

1) Set the cylinder head and piston rod bly
assembly (3) to tool U1. 1) Remove O-ring and backup ring (12).
2) Using tool U3, remove nut (5). 2) Remove snap ring (13) and dust seal (14).
q Width across flats of nut 3) Remove rod packing (15).
(Steering) : 46 mm 4) Remove bushing (16).
(Lift) : 70 mm 5) Remove O-ring (17).
(Bucket) : 75 mm
3) Remove piston assembly (6) and cylinder
head assembly (2).
9JF01067
9JF01065
4. Fine disassembly of piston assembly

Remove wear ring (9) and piston ring (10) from
piston (8).
9JF01080
58 WA200-6
Assembly 2. Fine assembly of piston assembly

a Take care not to damage the packings, dust 1) Using tool U6, expand piston ring (10).
seals, and O-rings, etc. a Set the tool to the piston ring and turn
a Do not insert each backup ring forcibly, but its handle by 8 – 10 turns to expand
warm it in water at 50 – 60°C and then insert it. the piston ring.
1. Fine assembly of cylinder head assembly

1) Using tool U4, press fit bushing (16).
9JF01073
9JF01069
2) Remove piston ring (10) from tool U6 and

install it to piston (8).
3) Using tool U7, shrink piston ring (10).
2) Install rod packing (15). 4) Install wear ring (9).
3) Using tool U5, install dust seal (14) and
secure it with snap ring (13).
4) Install backup ring and O-ring (12).
5) Install O-ring (17).
9JF01074
9JF01067
9JF01070
WA200-6 59
3. Assembly of cylinder head and piston rod 4. Cylinder head

assembly 1) Set cylinder (4) to tool U1.
1) Set cylinder head and piston rod assembly 2) Sling cylinder head and piston rod assem-
(3) for tool U1. bly (3) and install cylinder (4).
2) Install cylinder head assembly (2) and pis-
ton assembly (6) to the piston rod.
3) Using tool U3, tighten nut (5) to the speci-
fied torque.
q Width across flats of nut
(Steering) : 46 mm
(Lift) : 70 mm 9JF01062
(Bucket) : 75 mm
2 Threads of piston rod: Liquid
adhesive (LOCTITE No. 262 or
equivalent)
3 Nut (Steering):
785 ± 78.5 Nm {80 ± 8.0 kgm}
3 Nut: (Lift):
2,600 ± 260 Nm {265 ± 26.5 kgm}
3 Nut: (Bucket):
3) Using tool U2, install cylinder head
assembly (2) to the cylinder.
3 Cylinder head (Steering):
3,140 ± 314 Nm {320 ± 32.0 kgm}
539 ± 54.0 Nm {55 ± 5.5 kgm}
3 Cylinder head (Lift):
981 ± 98.1 Nm {100 ± 10 kgm}
3 Cylinder head (Bucket):
1,030 ± 103 Nm {105 ± 10.5 kgm}
9JF01065 4) Remove cylinder assembly (1) from tool
U1.
CED00174
60 WA200-6
5. Bucket positioner
Adjust the bucket positioner plate to the follow-
ing dimensions and tighten the bolts.
Dimension (a): 41.5 ± 1 mm
Dimension (b): 105 ± 2 mm
9JF115389
WA200-6 61
SEN03791-00

© 2007 KOMATSU
All Rights Reserved
62
SEN03792-00
WA200-6
WA200-6 70001 and up

Work equipment
Removal and installation of work equipment assembly .................................................................................. 2
WA200-6 1
Removal and installation of work 3. Move the machine to the rear and disconnect
equipment assembly 1 the bucket.
Removal 4. Sling bucket cylinder assembly (3) temporarily

k Stop the machine on a level ground and set and pull out rod-side pin (4) to disconnect the
the lock bar to the frame to fix the front and cylinder rod and bell crank. [*3]
rear frames. a Install block [1] between the cylinder bot-
k Lower the work equipment to the ground, tom and frame.
stop the engine, apply the parking brake, a Check the thickness and quantity of the
and put chocks under the tires. shims.
k
4
Disconnect the cable from the negative (–) Bucket cylinder assembly: 80 kg
1. Sling the bucket link temporarily and remove

bucket link pin (1). [*1]
4 Bucket link: 25 kg
a Secure the bucket link to the bell crank
with chains, etc.
a Check the thickness and quantity of the
shims.
AJF01023
2. Remove bucket hinge mounting pin (2). [*2]

k Never insert your fingers in the pin
holes.
a Check the thickness and quantity of the
shims.
2 WA200-6
5. Set supports [2] under the end of the lift arm 7. Disconnect boom positioner proximity switch
and release the residual pressure in the connector CN-F04 (7).
hydraulic piping.
8. Remove boom kick-out switch (8). [*5]
CJW11351
6. Sling lift cylinder assembly (6) temporarily and

remove mounting pin (5). [*4] 9. Sling lift arm and bell crank and bucket link
a Check the thickness and quantity of the assembly (10) temporarily and pull out mount-
shims. ing pin (11). [*6]
a When lowering the lift cylinder assembly, a Check the thickness and quantity of the
put a block on the axle. shims.
4 Lift cylinder assembly (1 piece): 80 kg
10. Lift off lift arm and bell crank and bucket link
assembly (10).
4 Lift arm and bell crank and bucket link
assembly: 750 kg
DBW01810
CJW11354
WA200-6 3
11. Sling bucket link assembly (12) temporarily, 14. Pull dust seal (17) and bushing (18) out of lift
pull out mounting pin (13), and remove the arm (16). [*8]
bucket link assembly from the bell crank
assembly. [*7]
4 Bucket link assembly: 25 kg
CJW11357
CJW11355
15. Pull dust seal (19) and bushing (20) out of bell
crank (14). [*8]
12. Sling bell crank assembly (14) temporarily and

pull out mounting pin (15).
13. Lift off bell crank assembly (14).

CJW11358
4 Bell crank assembly: 140 kg
CJW11356 16. Pull dust seal (21) and bushing (22) out of
bucket link (12). [*8]
CJW11359
4 WA200-6
Installation [*2]
q Carry out installation in the reverse order to Procedure for installing bucket hinge pin
removal. 1. Apply lubricant or grease to the inside surface
k When starting the engine, check that the of bushing of lift arm.
directional lever is in neutral and the park- 2 Inside of bushing:
ing brake is applied. Lubricant containing molybdenum
k When aligning the pin holes, use a bar. disulfide (LM-P or equivalent)
Never insert your fingers in the pin holes.
a Supply grease until it comes out of the joint. 2. Align the holes for mounting pin (2), by moving
a When you finish greasing every part, idle the the machine forward or backward using work
engine at low speed, and repeat 2 to 3 times equipment lever.
the operations of tilting and dumping of bucket k When starting the engine, check that
as well as raising and lowering of lift arm, to the directional lever is in neutral and
allow grease to spread all over the pin. the parking brake is applied.
[*1] 3. Insert shims on both sides so that clearances

Procedure for installing bucket link pin (b) on both sides will be the same.
1. Apply lubricant or grease to the inside surface q Clearance (b) (on each side):
of bushing of bucket link. Max. 1.5 mm
2 Inside of bushing: q Varieties of shim thickness: Only 1.5 mm
Lubricant containing molybdenum
disulfide (LM-P or equivalent) 4. Install mounting pin (2) and lock it with bolt
(26).
2. Sling the bucket link and align the holes for k Never insert your fingers in the pin
mounting pin (1). holes.
a Take care not to damage the pin.
3. Insert shims on both sides so that clearances
(a) on both sides will be the same.
q Clearance (a) (On each side):
Max. 1.5 mm
q Varieties of shim thickness: Only 1.5 mm
4. Install mounting pin (1) and lock it with bolt

(24).
holes.
5. After installing the pin, supply grease.

2 Bucket hinge pin:
Hyper White grease (G2-T or equiva-
lent)

2 Bucket link pin:
lent)
WA200-6 5
[*3] [*4]
Procedure for installing bucket cylinder pin (on Procedure for installing lift cylinder pin (on rod
rod side) side)
1. Apply lubricant or grease to the inside surface 1. Apply lubricant or grease to the inside surface
of bushing of bucket cylinder. of bushing of lift cylinder.
2 Inside of bushing: 2 Inside of bushing:
Lubricant containing molybdenum Lubricant containing molybdenum
disulfide (LM-P or equivalent) disulfide (LM-P or equivalent)
2. Align the holes for bucket cylinder pin (4) by 2. Align the holes for lift cylinder pin (5) by operat-
operating work equipment lever. ing work equipment lever.
k When starting the engine, check that k When starting the engine, check that
the directional lever is in neutral and the directional lever is in neutral and
the parking brake is applied. the parking brake is applied.
3. Insert shims on both sides so that clearances 3. Insert shims on both sides so that clearances
(c) on both sides will be the same. (d) on both sides will be the same.
q Clearance (c) (on each side): q Clearance (d) (on each side):
Max. 1.5 mm Max. 1.5 mm
q Varieties of shim thickness: Only 3.0 mm q Varieties of shim thickness: Only 1.5 mm
4. Install mounting pin (4) and lock it with bolt 4. Install mounting pin (5) and lock it with bolt
(27). (28).
k Never insert your fingers in the pin k Never insert your fingers in the pin
holes. holes.
a Take care not to damage the pin. a Take care not to damage the pin.
9JF01056 9JF01057
5. After installing the pin, supply grease. 5. After installing the pin, supply grease.
2 Bucket cylinder pin (on rod side): 2 Lift cylinder pin (on rod side):
Hyper White grease (G2-T or equiva- Hyper White grease (G2-T or equiva-
lent) lent)
6. Adjust the bucket positioner. For details, see [*5]

Testing and adjusting, "Testing and adjusting a Adjust the boom kick-out. For details, see
bucket positioner". Testing and adjusting, "Testing and adjusting
of boom kick-out switch".
6 WA200-6
[*6] [*7]
Procedure for installing lift arm pin (on frame Procedure for installing bucket link pin
side) 1. Apply lubricant or grease to the inside surface
1. Apply lubricant or grease to the inside surface of bushing of bucket link.
of bushing of lift arm. 2 Inside of bushing:
2 Inside of bushing: Lubricant containing molybdenum

Lubricant containing molybdenum disulfide (LM-P or equivalent)
disulfide (LM-P or equivalent)
2. Align the holes of bucket link mounting pin
2. Align holes of lift arm pin (11). (13).
a Secure the bell crank to the lift arm with
3. Insert shims on both sides so that clearances chains etc.
(e) on both sides will be the same.
q Clearance (e) (on each side): 3. Install mounting pin (13) and lock it with bolt
Max. 1.5 mm (31).
q Varieties of shim thickness: k Never insert your fingers in the pin
1.5 mm, 3.0 mm holes.

4. Install mounting pin (11) and lock it with bolt
(29).
holes.
9JF01058

2 Bucket link pin:
lent)

2 Lift arm pin (on frame side):
lent)
WA200-6 7
[*8]
Press fit bushings (18), (20), and (22) to lift arm
(16), bell crank (14), and bucket link (12) respec-
tively with hydraulic cylinder [3], etc., and then
install the dust seals.
2 Bushing: Grease (G2-LI)
a Apply grease to the seal so that the seal will
not be damaged.
9JF01060
a Press fit the dust seals (17), (19), and (21) with
the lip out.
q Installed dimension (g): 0.25 – 0.80 mm
q Installed dimension (h): 2 – 3 mm
9JF01061
q Greasing
Supply grease to each pin.
a Supply grease until it comes out of the
joint.
8 WA200-6
WA200-6 9
SEN03792-00

© 2007 KOMATSU
All Rights Reserved
10
SEN03793-00
WA200-6
WA200-6 70001 and up

Cab and its attachments
Removal and installation of operator's cab and floor frame assembly............................................................ 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 7
Removal and installation of air conditioner unit ............................................................................................ 15
WA200-6 1

operator's cab and floor frame
assembly 1
Removal
q Precautions for handling refrigerant 5. Remove right covers (3), (4), (5) and (6).
a Ask professional traders for collecting and 6. Remove hydraulic tank cover (7).
filling the refrigerant (R134a). k Loosen the hydraulic tank cap gradu-
a Never release the refrigerant (R134a) to ally to release the pressure in the
the atmosphere. hydraulic tank.
a If the refrigerant (R134a) gets inside ones
eyes, it may cause blindness. Therefore,
make sure to wear protective glasses
when collecting or filling the refrigerant.
hot coolant when disconnecting the
heater hoses and draining the cool-
ant. Wait until the coolant is cooled,
a The operator's cab of this machine forms one

unit with the floor frame.
1. Recover the refrigerant (R134a). [*1] 7. Remove left side covers (8), (9) and (10).
2. Loosen the radiator cap to drain the coolant. 8. Remove air conditioner external air filter case
6 Radiator: 17 l cover (11).

(1).
4. Remove right and left fenders and mounting

brackets (2).
4 Fender: 25 kg
2 WA200-6
9. Disconnect cab ground cable (12) from the 15. Disconnect the following hoses from Orbit-roll
lower right of the floor. valve (19). [*2]
q (20): LS port hose (Right)
10. Remove wiring harness clamp (13). q (21): P port hose (Left lower)
q (22): R port hose (Right lower)
11. Disconnect the following wiring harness con- q (23): L port hose (Right upper)
nectors from the lower right of the floor. q (24): T port hose (Left upper)
q (14): CN-FL2 a Disconnect the hoses from the right or left.
q (15): CN-FL1 a Plug the disconnected hoses to prevent oil
leakage.
a Put tags on the disconnected hoses and
record the installed positions etc. on them.
12. Disconnect 6 PPC hoses (16).

a Plug the disconnected hoses to prevent oil
leakage.
a Put tags to the disconnected hoses and 16. Disconnect the following wiring harness con-
record the installed positions etc. on them. nectors from the lower left of the floor.
q (25): CN-LR1
13. Remove wiring harness clamp (17). q (26): CN-LR10
q (27): CN-LR2
14. Remove hose clamp (18). q (28): CN-LR3
q (29): CN-LR12
q (30): CN-LR4
q (31): CN-BL1
q (32): CN-LT1
q (33): CN-LT2
q (34): CN-LR7
q (35): CN-LR11
q (36): CN-LR6
a Put tags on the disconnected connectors
and record the installed positions etc. on
them.
WA200-6 3
21. Remove 2 air conditioner pipe clamps (41).
22. Disconnect air conditioner pipes (42) and (43).
23. Disconnect heater hoses (44) and (45).

a Put tags to the disconnected connectors
and record the installed positions etc. on
them.
18. Disconnect 2 washer hoses (38) from the

engine compartment side.
24. Disconnect wiring harness connector CN-L34

(46).
25. Remove 2 brake valve hose clamps (47).
26. Disconnect brake valve hose (48). [*3]

a Plug the disconnected hose to prevent oil
leakage.
a Put a tag to the disconnected hose and
19. Remove 2 air conditioner hose clamps (39). record the installed position etc. on it.
20. Remove bracket (40).
4 WA200-6
27. Remove locknut (49) and disconnect brake 33. Remove front mount covers (59) on the right
valve linkage (50). [*4] and left sides.
28. Remove 4 mounting bolts (51) and brake valve

(52).
a Leave brake valve (52) on the machine
with the hoses connected.
34. Remove 4 operator's cab mounting nuts (60).

[*5]
29. Set parking brake lever (53) in the OFF

(Release) position. (Push down the lever fully
in the direction of the arrow.
30. Remove cover (54).
35. Lift off operator's cab and floor frame assembly

(61).
a Check that all the wiring and piping are
disconnected.
4 Operator's cab and floor frame assem-
bly: 840 kg
31. Loosen locknut (55) and remove pin (56).
32. Pull out grommet (57) and brake cable (58)

together toward below the floor.
WA200-6 5
Installation [*5]
q Carry out installation in the reverse order to 3 Operator's cab mounting nuts (60):
removal. 824 – 1,030 Nm {84 – 105 kgm}
[*1]
a When installing the hoses of the air conditioner q Refilling with oil (Hydraulic tank)
circuit, take care that dirt, dust, water, etc. will Add oil through the oil filler to the specified
not enter them. level. Run the engine to circulate the oil
a When installing each air conditioner hose, through the system. Then, check the oil level
check that O-ring (70) is fitted to it. again.
5
Hydraulic oil (For details, see "Table of
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt. q Refilling with coolant
3 Threaded part of hose (M16 × 1.5): Add coolant through the coolant filler to the
12 – 15 Nm {1.2 – 1.5 kgm} specified level. Run the engine to circulate the
3 Threaded part of hose (M22 × 1.5): coolant through the system. Then, check the
20 – 25 Nm {2.0 – 2.5 kgm} coolant level again.
30 – 35 Nm {3.0 – 3.5 kgm}
and lubricants")

ant (R134a).
[*2]
Bleed air from the steering circuit. For details, see
Testing and adjusting, "Bleeding air from steering
circuit".
[*3]
Bleed air from the brake system. For details, see
Testing and adjusting, "Bleeding air from brake cir-
cuit".
[*4]
Adjust the brake pedal linkage. For details, see
Testing and adjusting, "Testing and adjusting brake
pedal linkage".
6 WA200-6
Removal and installation of a If the glass is narrow, you may cut the
operator's cab glass adhesive by the following method. Insert
a fine wire [2] (piano wire, etc.) in the
(Stuck glass) 1 adhesive and grip its both ends with pliers
Special tools [3], etc. (or hold them by winding them
onto something) and cut the adhesive with
New/Remodel
the wire.
Necessity
Sketch
Q'ty
1 793-498-1120 Clear plate t 2

1 2 793-498-1130 Plate t 2
X 3 793-498-1110 Magnet t 2
2 793-498-1210 Lifter t 2
(Suction cups)
Removal
a All sides of each glass of the operator's cab of
this machine are stuck.
a Remove the window glass to be replaced a The broken window glass may be
according to the following procedure. removed with knife [4] and a screwdriver.
(If the screwdriver is applied directly to the
1. Using seal cutter [1], cut the adhesive between normal window glass, the glass will be
broken window glass (1) and operator's cab broken.)
(2). a When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
forward.
2. Remove the window glass.
WA200-6 7
Installation
1. Using scraper [5], remove the remaining adhe-
sive.
a Do not scratch the paint.
4. Stick double-sided adhesive tape (4) along the

inside edge of the glass sticking section.
q Size of double-sided adhesive tape:
7 × 4.8 mm
2. Remove oil, dust, dirt, etc. from the sticking a When sticking the double-sided adhesive
surfaces of cab (2) and window glass (3) with tape, do not touch the cleaned surface as
white gasoline. long as possible.
a If the sticking surfaces are not cleaned a Do not remove the release tape of the
well, the glass may not be stuck perfectly. double-sided adhesive tape on the glass
a Clean the all black part on the back side of sticking side before sticking the glass.
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
a Take care the corner (part (b)) of double-

sided adhesive tape will not float.
3. When the adhesive was removed with the

scraper and if any paint was flaked off, coat the
bare part with paint.
a If the glass is installed without repairing
the bare part, that part will be rusted.
a Do not apply paint to the part which will be
coated with primer.
8 WA200-6
a When sticking the double-sided adhesive 3) Using tool X2 (suction cups), place win-
tape around a side or a rear window glass, dow glass (3) on tool X1-1 (5 mm spacer)
start at center of the top and make a clear- and match it to the operator's cab.
ance of about 5 mm at end joint (c).
CWW11608
4) Check the clearance between window

5. Position the replacement glass. glass (3) and operator's cab (2) on both
1) Stick X1-2 (thin steel sheet) to tool X1-1 sides and adjust it evenly.
(spacer) with adhesive. 5) Stick tape [6] between window glass (3)
q Spacer thickness ( t) : 5 mm and operator's cab (2) and draw position-
2) Match tool X1-3 (magnet) to tools X1-1 ing line (a).
and X1-2 and set them to the 2 lower 6) Cut the tape between window glass (3)
places of the window glass sticking part of and operator's cab (2) with a knife, and
operator's cab (2). then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab till
installing the window glass.
WA200-6 9
6. Apply primer. a Parts to be coated with primer: Apply

a The expiration date of primer (5) is 4 the primer all over dimension (d) on
months after the date of manufacture. Do the outside of the double-sided adhe-
not use primer (5) after this limit. sive tape.
a Use the primer within 2 hours after open- q Dimension to apply primer (d):
ing it. 23 mm
a Even if the primer is sealed again just after a After applying the primer, leave it for
it is opened, use it within 24 hours after it at least 5 minutes (within 8 hours) to
is opened for the first time. dry.
(Discard the primer 24 hours after it is a If the glass primer is applied by mis-
packed.) take, wipe it off with white gasoline.
1) Stir the primers for paint and glass suffi- (If wrong primer is applied, the glass
ciently before using them. will not be stuck.)
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it.
(If the primer is opened just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
4) Evenly apply glass primer (8) to the black

3) Evenly apply paint primer (7) to the parts part of window glass (3) to be stuck.
on the outside of double-sided adhesive 2 Glass primer: SUNSTAR GLASS
tape on operator's cab (2) which will be PRIMER 580 SUPER
coated with the adhesive. a Do not apply the primer more than 2
2 Paint primer: SUNSTAR PAINT times.
PRIMER 580 SUPER (If it is applied more than 2 times, its
a Do not apply the primer more than 2 performance will be lowered.)
times. a Parts to be coated with primer: Apply
(If it is applied more than 2 times, its the primer to the sticking surface of
performance will be lowered.) window glass (3) and all over dimen-
sion (d) on double-sided adhesive
tape (4) and operator's cab (2).
q Dimension to apply primer (d):
23 mm
10 WA200-6
a Do not apply the primer to the 1) Break aluminum seal (10) of the outlet of
boarder about 5 mm wide between adhesive cartridge (9) and install the noz-
the black part and transparent part of zle.
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off completely with white
gasoline.
(If wrong primer is applied, the glass
will not be stuck.)
2) Cut the tip of adhesive nozzle (11) so that

dimensions ( f) and (g) will be as follows.
q Dimension ( f) : 10 mm
q Dimension (g): 12 mm
3) Set adhesive cartridge (9) to caulking gun

[7].
a An electric caulking gun is more effi-
cient.
7. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The expiration date of the adhesive is 4
months after the date of manufacture. Do
not use the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove all
the hardened part from the nozzle tip.
WA200-6 11
4) Remove release tape (13) of the double-

sided adhesive tape on the glass side.
8. Install window glass (3).

a If the glass is positioned wrongly, the
5) Apply adhesive (12) to the outside of dou- adhesive must be removed and cleaned,
ble-sided adhesive tape (4) of the opera- and then the primer and adhesive must be
tor's cab. applied again. Accordingly, position the
a Before applying the adhesive, check glass carefully when sticking it.
that the primer is applied to the sur- 1) Similarly to step 1, match tools X1-1, X1-
face to which the adhesive will be 2, and X1-3 and set them to the 2 lower
applied. places of the window glass sticking part of
operator's cab (2).
a Apply adhesive (12) to dimensions (h)

and ( j) of double-sided adhesive tape 2) Using tool X2, raise and place window
(4) of operator's cab (2). glass (3) on tool X1-1 (5-mm spacer) and
q Dimension (h): 10 mm stick it to the operator's cab.
q Dimension ( j ) : 12 mm (Approx. a Match the lines of the match tapes
twice as high as adhesive tape) stuck in step 1.
a Apply adhesive (12) higher than dou- a Stick the glass within 10 minutes after
ble-sided adhesive tape (4). applying the adhesive.
a Apply the adhesive evenly. a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
12 WA200-6
9. Cure the stuck window glass for a certain time.

a Curing time before removing tool X1-1 (5-
mm spacer) (at temperature of 20°C and
humidity of 60%): 10 hours
a Curing time before operating machine:
1 day
10. If the front glass and both front glasses are

replaced, seal them.
1) Stick masking tapes (14) along the parts to
be sealed shown in the figure.
a Stick the masking tapes to both inside
and outside of the operator's cab.
a Check clearance ( k) between the

front side of the front glass and each
side and adjust it evenly.
q Clearance ( k ) : 5 mm
3) After sticking window glass (3), press it

evenly.
a Press all over the window glass to the
degree that the window glass will be
stuck to the double-sided adhesive
tape.
a Do not press the window glass too
strongly.
WA200-6 13
2) Fill the joint of the glasses with caulking

material (15).
a The expiration date of the following
caulking material is 4 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
2 Caulking material:
SUNSTAR PENGUINE
SEAL NO. 2505
CPW11631
3) Remove the caulking material projected

from the joint with cardboard [8], etc.
CPW11632
4) Remove the masking tapes from the win-

dow glass.
11. Remove the primer and adhesive from the

operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glass, do not make an
impact to it.
14 WA200-6
Removal and installation of air 3. Pull out each switch from panel cover (1) on
conditioner unit 1 the left side of the operator's seat and discon-
nect the following connectors.
Removal q (2): CN-L10
k Stop the machine on a level ground and set q (3): CN-L11
the lock bar to the frame to fix the front and q (4): CN-L09
rear frames. a Different specifications use different
k Lower the work equipment to the ground, switches and connectors.

CPW11631
the atmosphere.
tive glasses when collecting or filling 4. Pull out each switch from panel cover (1) on
the refrigerant. Collecting and filling the right side of the operator's seat and discon-
work must be conducted by a qualified nect the following connectors.
person. q (5): CN-L19
k If the radiator coolant temperature is q (6): CN-L07
high, you may scald yourself with the q (7): CN-L08
hot coolant when disconnecting the q (8): CN-L06
heater hoses and draining the cool- a Different specifications use different
ant. Wait until the coolant is cooled, switches and connectors.
1. Recover the refrigerant (R134a). [*1]

6 Radiator: 17 l CPW11631
WA200-6 15
5. Remove 8 mounting bolts (1a) and panel cover 8. Remove monitor panel assembly (11).
(1). [*2]
CPW11631
CPW11631
9. Disconnect wiper water hose (12) from the

6. Remove 2 pieces (9) and 1 piece (10) of the front outside of the cab.
monitor panel mounting bolts. [*3]
10. Remove wiper blades (13).
CPW11631
CPW11631
7. Reverse monitor panel assembly (11) halfway

and disconnect the following connectors from 11. Disconnect wiper water hose (14) from the
the rear side. inside of the cab.
(12): —
(13): CN-L30 12. Disconnect wiper wiring harness connector
(14): CN-L28 (15).
(15): CN-L27
(16): CN-L26 13. Remove wiper motor assembly (16).
(17): CN-L25
(18): CN-L29
(19): CN-L24
a Take care not to strain the wiring since it is
short.
CPW11631
16 WA200-6
14. Remove left duct (17) and right duct (18). 20. Disconnect wiring harness connector (28) and
fuse (29).
CPW11631
CPW11631
15. Disconnect right lower duct hose (19).

21. Remove right cover (30).
16. Remove 8 mounting bolts (20) and plate (21).
CPW11631
CPW11631
22. Disconnect heater hoses (32) and (33) and air

17. Remove left cover (22). conditioner pipes (34) and (35) at the lower
right of air conditioner unit (31).
18. Disconnect the following wiring harness con- a Plug the disconnected hoses and ports to
nectors. prevent foreign matter from entering them.
q (23): CN-C50 [*4]
q (24): CN-C49
q (25): CN-AL1 23. Disconnect wiring harness connector (36).
19. Remove air conditioner internal air filter case

(26).
CPW11631
CPW11631
WA200-6 17
24. Disconnect blower motor wiring harness con- 26. Blower motor assembly
nector (37) from the lower left of the operator's 1) Remove side cover (39) and front cover
cab floor and pull out the wiring harness and (40) at the lower left of the operator's cab.
grommet (38) together above the floor. 2) Remove air conditioner external air filter
case (41).
CPW11631
CPW11631
25. Remove air conditioner assembly (31) upward.

a Check that all the wiring and piping are 3) Remove air conditioner external air duct
disconnected. (42) from the lower left of the floor.
CPW11631
4) Remove the 5 mounting bolts and blower

motor assembly (43).
a Remove the 5 bolts indicated with the
arrows. (The ones marked with
among them are used to fix the exter-
*
nal air filter case, too.)
CPW11631
CPW11631
18 WA200-6
Installation
removal.
[*1]
a When installing the hoses of the air conditioner
CPW11631 circuit, take care that dirt, dust, water, etc. will
not enter them.
check that O-ring (70) is fitted to it.
12 – 15 Nm {1.2 – 1.5 kgm}
20 – 25 Nm {2.0 – 2.5 kgm}
CPW11631 30 – 35 Nm {3.0 – 3.5 kgm}
CPW11631

ant (R134a).
WA200-6 19
[*2]
3 Panel cover mounting bolt (1a):
3.4 – 4.4 Nm {0.35 – 0.45 kgm}
[*3]
3 Monitor panel mounting bolts (9) and (10):
2.75 – 2.94 Nm {0.28 – 0.30 kgm}
[*4]
a Do not remove the plugs installed when the
piping was disconnected to prevent entry of
foreign matter until just before connecting the
piping.
2 O-ring and threaded part:
Compressor oil for R134a
(SANDEN: SP-10 or equivalent)
3 Hose adapter mounting bolt (44):
8 – 12 Nm {0.8 – 1.2 kgm}
CPW11631

and lubricants")
20 WA200-6
WA200-6 21
SEN03793-00

© 2007 KOMATSU
All Rights Reserved
22
SEN03794-00
WA200-6
WA200-6 70001 and up

Electrical system
Removal and installation of monitor panel ...................................................................................................... 2
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of HST controller assembly..................................................................................... 6
Removal and installation of KOMTRAX terminal assembly ............................................................................ 7
WA200-6 1
Removal and installation of 3. Remove 8 mounting bolts (1a) and panel cover
monitor panel 1 (1). [*1]
Removal
rear frames.
1. Pull out each switch from panel cover (1) on

the left side of the operator's seat and discon-
q (2): CN-L10 4. Remove 2 pieces (9) and 1 piece (10) of the
q (3): CN-L11 monitor panel mounting bolts. [*2]
q (4): CN-L09
a Different specifications use different
switches and connectors.
2. Pull out each switch from panel cover (1) on

the right side of the operator's seat and discon-
q (5): CN-L19
q (6): CN-L07
q (7): CN-L08
q (8): CN-L06
a Different specifications use different
switches and connectors.
2 WA200-6
5. Reverse monitor panel assembly (11) halfway Installation

and disconnect the following connectors from q Carry out installation in the reverse order to
the back side. removal.
q (12): –
q (13): CN-L30 [*1]
q (14): CN-L28 3 Panel cover mounting bolt (1a):
q (15): CN-L27 3.44 – 4.40 Nm {0.35 – 0.45 kgm}
q (16): CN-L26
q (17): CN-L25 [*2]
q (18): CN-L29 3 Monitor panel mounting bolts (9) and (10):
q (19): CN-L24 2.75 – 3.53 Nm {0.28 – 0.30 kgm}
a Take care not to strain the wiring since it is
short.
6. Remove monitor panel assembly (11).
7. Remove bracket (20) from monitor panel

assembly (11).
WA200-6 3
Removal and installation of 6. Remove wiring harness clamps (9) and (10).
engine controller assembly 1
7. Remove bracket (11).
Removal
k Stop the machine on a level ground and set 8. Remove wiring harness clamps (12) and (13).
rear frames. 9. Remove bracket (14).

a Check that the cover is locked securely.
10. Disconnect 5 mounting bolts (15) and engine

controller assembly (16). [*2]
2. Remove wiring harness clamps (2) and (3).
4. Remove 2 connector mounting bolts (5). [*1]

a Width across flats of hexagonal socket of
mounting bolt: 4 mm
5. Disconnect connectors CN-EC2 (6), CN-EC1

(7) and CN-EC3 (8).
4 WA200-6
Installation
removal.
a Before installing, remove foreign materials
(dirt, water, etc.) from the wiring harness con-
nector of the engine controller assembly.
[*1]
3 Wiring harness connector mounting bolt:
3 ± 0.1 Nm {0.31 ± 0.01 kgm}
[*2]
3 Engine controller assembly mounting bolt:
24 ± 4 Nm {2.45 ± 0.4 kgm}
WA200-6 5
Removal and installation of HST Installation

controller assembly 1 q Carry out installation in the reverse order to
removal.
Removal a Before installing, remove foreign materials
k Stop the machine on a level ground and set (dirt, water, etc.) from the wiring harness con-
the lock bar to the frame to fix the front and nector of the HST controller assembly.
rear frames.
1. Slide the operator's seat to the forward end.
2. Remove cover (1) from the rear of the opera-

tor's seat.
3. Disconnect wiring harness connector CN-HST

(2).
4. Remove HST controller (3).
6 WA200-6
Removal and installation of 5. Disconnect wiring harness connector CN-L80

KOMTRAX terminal assembly 1 (4) of the chassis from KOMTRAX terminal
assembly (3).
Removal a Disconnect the machine wiring harness
k Stop the machine on a level ground and set first and then disconnect the antenna
the lock bar to the frame to fix the front and cables (If the antenna cables are discon-
rear frames. nected first, an antenna cable disconnec-
k Lower the work equipment to the ground, tion error is saved in the KOMTRAX). [*1]
stop the engine, apply the parking brake, a Remove CN-L80 (4) by loosening the
and put chocks under the tires. hexagon socket head screw at its center.
k Disconnect the cable from the negative (–) [*2]
6. Disconnect antenna cable connectors (5) and
1. Open the right door of the operator's cab. (6) from KOMTRAX terminal assembly (3).
a Lock the door securely.
2. Turn over and fix floor mat (1) under cover (2).
3. Remove right armrest outside cover (2) of the

operator's seat.
Installation
removal.
a Before installing, remove foreign materials
4. Remove the 4 mounting bolts and then (dirt, water, etc.) from the wiring harness con-
KOMTRAX assembly (3). nector of the KOMTRAX terminal assembly.
[*1]
a First, connect the antenna cable connec-
tors then the wiring harness connector of
the chassis.
[*2]
3 Hexagon socket head screw at center of wir-
ing harness connector CN-L80 (4):
2.82 Nm {0.288 kgm}
WA200-6 7
SEN03794-00

© 2007 KOMATSU
All Rights Reserved
8
SEN03093-00
WA200-6
WA200-6 70001 and up
90 Diagrams and drawings 1
Hydraulic diagrams and drawings

Hydraulic circuit diagram................................................................................................................................. 3
WA200-6 1
SEN03093-00 90 Diagrams and drawings
2 WA200-6
Hydraulic circuit diagram
Hydraulic circuit diagram WA200-6
1
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03093-00
WA200-6
3
WA200-6 5
SEN03093-00

©2007 KOMATSU
All Rights Reserved
6
SEN03094-01
WA200-6
WA200-6 70001 and up
90 Diagrams and drawings 1
Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Connector arrangement diagram .................................................................................................................. 23
WA200-6 1
SEN03094-01 90 Diagrams and drawings
2 WA200-6
Electrical circuit diagram 1/9
Electrical circuit diagram WA200-6
1
Electrical circuit diagram 1/9

Common to WA200-6 and WA250-6
SEN03094-01
WA200-6
3
Electrical circuit diagram 2/9 Electrical circuit diagram 2/9
Common to WA200-6 and WA250-6 WA200-6
SEN03094-01
WA200-6
5
SEN03094-01
WA200-6
7
SEN03094-01
WA200-6
9
SEN03094-01
WA200-6
11
SEN03094-01
WA200-6
13
SEN03094-01
WA200-6
15
SEN03094-01
WA200-6
17
SEN03094-01
WA200-6
19
Electrical circuit diagram Electrical circuit diagram
WA200-6 WA200-6
SEN03094-01
WA200-6
21
Connector arrangement diagram
Connector arrangement diagram WA200-6 WA200-6
Number Address of Number Address of Number Address of

Connector No. Model Component name Connector No. Model Component name Connector No. Model Component name
of pins stereogram of pins stereogram of pins stereogram
— — 2 Water in fuel sensor F11 DT-T 2 Steering pump pressure switch L79 — 5 KOMTRAX engine cut relay P-6
AL1 DT-T 6 Intermediate connector T-1 F12 DT-T 2 Emergency steering pressure switch L80 DRC key A 40 KOMTRAX controller T-8
AMBAIR
PRESURE — 3 Ambient pressure sensor AC-3 F14 DT-T 2 Brake oil temperature switch C-1 L100 Terminal 1 GND (floor) Y-3
B01 DT-T 2 Rear work lamp RH K-9 F15 DT2 3 Lift arm angle sensor (for load meter) A-3 L101 — 6 FR press select relay AB-7
B02 DT-T 2 Rear work lamp LH M-7 F16 DT2 3 Lift arm bottom sensor (for load meter) F-1 L102 — 5 VIS power hold relay Z-8
B03 DT-T 2 Back buzzer M-7 F17 DT2 3 Lift arm rod sensor (for load meter) F-1 L103 — 5 Motor 2 solenoid relay Z-8
B05 DT-T 2 Coolant level sensor J-9 FL1 DT-T 12 Intermediate connector D-7, V-1 L104 — 5 Fan reverse solenoid relay Z-8
B05 Terminal 1 GND (license lamp) M-7 FL2 DT-T 6 Intermediate connector D-8, V-2 L105 — 5 Electrical parking brake relay AA-7
B06 08027 2 (R) Window sealed washer motor K-9 FL3 DT-T 4 Intermediate connector W-2 L106 — 5 Neutral safety relay AA-7
B07 08027 2 (F) Window sealed washer motor M-5 FL4 DT-T 6 Intermediate connector V-2 L107 — 5 Engine controller cut 1 relay Z-7
B08 DT-T 2 Diode M-3 FLC DT-T 3 Front combination lamp RH C-6 L108 — 5 Engine controller cut 2 relay Z-8
B09 DT-T 2 Diode K-2 FLC1 DT-T 3 Front combination lamp LH G-1 L109 — 5 Back alarm/lamp 1 relay AB-7
BL1 DT-T 6 Intermediate connector X-2 FLH DT-T 3 Head lamp RH B-5 L110 — 5 ECSS relay AB-7
BOOST PRESS &
INT — 4 Boost pressure sensor AE-4 FLH DT-T 3 Head lamp LH G-1 L111 — 5 HST solenoid safety relay AB-8
BR1 DT-T 4 Intermediate connector M-8 FS1 — 15 Fuse box V-9 L112 — 5 Air clearner clog relay AB-8
C04 DT 2 Front work lamp (RH) 24V/70W E-8 FS2 — 15 Fuse box V-9 L113 — 5 Boom kick out relay AB-9
C05 DT 2 Front work lamp (LH) 24V/70W J-9 FUEL RAIL — 3 Common rail pressure sensor AG-5 L114 — 5 Bucket leveler relay AA-9
PRESS
C07 YAZAKI 2 Room lamp I-9 HEAD L DT-T 6 Intermediate connector H-1 L115 — 5 Detent active relay AA-9
7123-2228
YAZAKI
C08 -08056 1 Door switch (LH) (room lamp) H-9 HEAD R DT-T 6 Intermediate connector A-4 L116 — 5 Horn relay AA-9
C09 YAZAKI 1 Door switch (RH) (room lamp) E-8 HST DRC 40 HST controller Z-6 L117 — 5 Small lamp relay LH AA-6
-08056
C10 Terminal 1 GND to radio body F-9 INJ. CYL. 1 & 2 — 4 Injector #1 & #2 AF-4 L118 — 5 Small lamp relay RH AA-5
C11 YAZAKI PA 9 AM/FM radio E-8 INJ. CYL. 3 & 4 — 4 Injector #3 & #4 AG-5 L119 — 5 Head lamp relay LH AA-5
C12 M 2 Speaker LH I-9 J01 M6409-0075 20 Joint connector R-6 L120 — 5 Head lamp relay RH AA-5
C13 M 2 Speaker RH H-9 J02 M6409-0255 20 Joint connector R-6 L121 — 5 Stop lamp relay Z-5
C14 198-Z11-2650 2 Lighter D-7 J03 M6409-0071 20 Joint connector V-1 L122 — 5 Front work lamp relay AA-4
C15 DT 3 Intermediate connector J04 M6409-0075 20 Joint connector Y-9 L123 — 5 Rear work lamp relay AB-4
C16 DT 2 Warning lamp (beacon) J05 M6409-0072 20 Joint connector Y-9 L124 — 6 Hazard/turn signal relay AB-4
C17 SWP 6 Warning lamp (beacon) switch (If equipped) J06 M6409-0071 20 Joint connector Y-9 L125 — 5 Hazard relay AB-4
C18 SWP 6 Warning lamp (pat. light) switch (If equipped) J07 M6409-0072 20 Joint connector R-8 L126 — 5 Back alarm/lamp 2 relay AB-6
C18 Terminal 1 GND (cabin) E-8 J08 M6409-0075 20 Joint connector Q-4 L151 — 5 Front work lamp (yellow) relay (If equipped)
C19 SWP 6 Rear glass heater switch G-9 J09 M6440-0128 20 Joint connector Y-9 L152 — 5 Warning lamp (beacon) relay
C20 — 5 Relay for rear glass heater G-9 J10 M6409-0255 20 Joint connector Y-9 L153 — 5 Warning lamp (pat.light) relay (If equipped)
C21 YAZAKI 1 Rear glass heater H-9 J11 M6440-0135 20 Joint connector Z-8 L154 — 6 Warning lamp (pat.light) switch relay (If equipped)
7116-2270
C22 YAZAKI 1 Rear glass heater J-9 J12 M6409-0075 20 Joint connector Z-8 LR1 #8 1 Intermediate connector N-3, AB-2
7116-2270
C23 DT 4 Intermediate connector D-8 J13 M6409-0128 20 Joint connector R-6 LR2 DT-T 12 Intermediate connector N-3, AB-2
C47 — 22 Manual A/C control amp F-9 J14 M6409-0075 20 Joint connector Z-8 LR3 DT-T 6 Intermediate connector N-2, AB-1
C48 — 14 Manual A/C control amp F-9 J15 M6440-0128 20 Joint connector O-4 LR4 #8 1 Intermediate connector N-2, AB-1
C49 DT-T 12 Intermediate connector F-1 J16 M6409-0128 20 Joint connector Z-7 LR6 #8 1 Intermediate connector M-2, X-1
C50 DT-T 12 Intermediate connector F-1 J17 M6409-0072 20 Joint connector Z-7 LR7 DT-T 12 Intermediate connector M-3, X-1
C140 DRC 40 Tachograph controller L02 DT-T 4 Starting switch R-9 LR10 DT-T 3 Intermediate connector N-3, AB-2
C142 YAZAKI 17 Tachograph L03 DT-T 4 Speed range selector switch R-8 LR11 DTP 4 Intermediate connector M-3, X-1
7119-3170
CAM SENSOR — 3 G sensor AD-2 L04 SWP 8 Combination lamp switch T-1 LR12 #8 1 Intermediate connector N-2, AB-1
CAN1 DT-T 3 CAN resistor AH-2 L05 S 10 Wiper switch (front, rear) S-1 LT1 DT-T 12 Intermediate connector M-3, X-2
CAN2 DT-T 3 CAN resistor S-1 L06 SWP 6 Hazard switch R-6 LT2 DT-T 6 Intermediate connector M-3, X-2
CHK0 X 1 KOMTRAX inspection connector P-6 L07 SWP 6 Front work lamp switch Q-5 MF1 DTM 12 Multi function lever switch
OIL PRESURE
CHK1 X 1 KOMTRAX inspection connector P-6 L08 SWP 6 Rear work lamp switch R-6 SWITCH — — Engine pressure switch (low) AG-1
CL1 SWP 6 Intermediate connector A-5, O-2 L09 SWP 6 ECSS switch T-1 PD1 DT-T 6 Throttle pedal switch O-2
CL2 SWP 8 Intermediate connector C-6, O-3 L10 SWP 6 Monitor 1 switch U-1 PD2 DT-T 2 Throttle pedal switch O-2
CL31 DT-T 2 Diode L11 SWP 6 Monitor 2 switch T-1 R00 Terminal 1 GND M-7
CL32 DT-T 2 Diode L13 DT-T 2 Horn switch T-1 R01 Terminal 1 Battery relay A-8
COOLANT TEMP — 2 Engine coolant temperature sensor AD-4 L15 DT-T 4 FNR switch S-2 R02 Terminal 1 Slow blow fuse D-8
CP3 PUMP — 2 IMA fuel pump actuator AH-3 L16 SWP 6 Loadmeter A/B (If equipped) U-1 R03 Terminal 1 Slow blow fuse D-9
REGULATOR
CRANK SENSOR — 3 Ne sensor AD-1 L17 SWP 6 Loadmeter total (If equipped) V-1 R04 Terminal 1 Battery relay A-8
D01 SWP 8 Diode O-8 L19 SWP 6 Parking brake switch S-7 R05 Terminal 1 Slow blow fuse C-9
D02 SWP 8 Diode O-8 L24 AMP 070 20 Monitor panel R-2 R05A Terminal 1 Slow blow fuse C-9
D03 SWP 8 Diode O-8 L25 AMP 070 18 Monitor panel R-2 R06 Terminal 1 Slow blow fuse C-9
D07 DT-T 2 Diode O-7 L26 AMP 070 12 Monitor panel R-2 R11 Terminal 1 Slow blow fuse C-9
D08 DT-T 2 Diode O-7 L27 AMP 070 18 Monitor panel Q-3 R15 Terminal 1 Battery relay A-7
D09 DT-T 2 Diode O-7 L28 AMP 070 12 Monitor panel Q-4 R16 Terminal 1 Battery relay A-7
D10 DT-T 2 Diode O-7 L29 AMP 070 12 Monitor panel T-7 R20 Terminal 1 GND (rear frame) J-1
D21 DT-T 2 Diode J-1 L30 AMP 070 14 Monitor panel S-7 R21 DT-T 2 Fuel level sensor M-4
D22 DT-T 2 Diode J-1 L34 DT-T 2 Stop lamp switch W-2 R22 DT-T 6 Rear combination lamp LH M-6
E01 DT-T 2 Starting motor safety relay AE-5 L35 DT 2 PPC valve with electrical detent Q-9 R23 DT-T 6 Rear combination lamp RH K-9
SUMITOMO
E02 6189-0442 3 Alternator M-5 L36 DT 2 PPC valve with electrical detent R-6 R24 DT-T 2 License lamp (If equipped) L-8
E03 Terminal 1 Alternator terminal B M-6 L37 DT 2 PPC valve with electrical detent R-6 R26 Terminal 1 GND (rear frame) G-1
E05 Terminal 1 Heater relay terminal B B-9 L38 DT-T OPT 2 UN switch +24 V (If equipped) Z-4 R29 DT-T 2 Oil fan EPC solenoid L-8
E06 Terminal 1 Heater relay B-9, L-3 L39 DT-T OPT 2 Key on +24 V (If equipped) Z-4 R59 DT-T 2 Fan reverse solenoid L-8
E06A DT-T 2 Diode L-2 L45 DT-T 6 Auto lubrication AB-2 R90 Terminal 1 Heater relay terminal E K-2
E07A Terminal 1 Heater relay terminal A AF-5 L46 M 2 Buzzer W-9 SV DT-T 12 Service connector Y-8
E07B — 1 Electrical intake air heater AF-5 L47 DT 2 Parking brake indicator switch Y-3 T01 DT-T 4 HST pump solenoid AC-5
E10 DT-T 2 Freon compressor magnet clutch AH-3 L48 08027 6 Wiper timer X-2 T01A — 2 Diode AD-4
E14 Terminal 1 GND (engine controller) AF-6 L49 08027 4 Flasher AA-3 T01B — 2 Diode AD-4
E15 Terminal 1 GND (engine controller) AF-6 L50 DT-T 12 Intermediate connector Z-6 T05 DT-T 2 Clutch control EPC solenoid N-2, AM-7
E19 Terminal 1 Starting motor safety relay AG-7 L52 M 4 Rear wiper motor X-9 T06 DT-T 2 HST motor 1 EPC solenoid L-1, AI-5
E20 Terminal 1 Starting motor safety relay AH-8 L53 DT 2 Parking brake remind switch Z-5 T07 DT-T 4 HST motor 2 solenoid & motor 2 overrun solenoid L-1, AI-7
E21 Terminal 1 Starting motor terminal C AG-8 L54 DT-T 3 Variable shift control switch T-8 T09 DT-T 4 Speed sensor H-1, AJ-8
E30 Terminal 1 Starting motor terminal B AH-8 L55 DT 2 Air suspension seat Z-5 T10 DT-T 2 HST oil temperature sensor L-1, AJ-8
E41 DT-T 2 Intermediate connector AH-1 L57 M 6 Front wiper motor Q-3 T11 DT-T 3 HST oil pressure sensor L-1, AI-6
E42 DT-T 2 Intermediate connector AH-2 L58 M 2 12V option converter output Z-4 T12 DT-T 2 Accumurator pressure switch M-1
EC1 DRC 60 Engine controller module AF-1 L59 DT-T 4 Bucket lever LDM cancel switch (If equipped) Q-6 T13 — 1 HST filter clogging sensor M-1
EC2 DRC 50 Engine controller module AD-2 L60 DT-T 6 Intermediate connector Z-4 T14 Terminal 1 GND N-1
EC3 DTP 4 Engine controller module AF-1 L61 DT-T 4 Boom lever TCS cancel switch Q-6 T31 DT-T 2 Diode
ER1 DT-T 12 Intermediate connector AF-5 L62 DT-T 4 Intermediate connector Q-6 T32 DT-T 2 Diode
ER2 DT-T 12 Intermediate connector AF-6 L63 SWP 6 FNR active switch Q-9 TEL DT-T 12 Intermediate connector P-6
ER3 DT-T 2 Intermediate connector AF-5 L64 SWP 6 Traction switch Q-9 TOOL PORT — 3 CAN resistor AE-1
F01 08160-70001 2 Horn (high) A-4 L65 SWP 6 Work lamp (yellow) (If equipped) R-6 Z01 DT-T 2 Diode
F02 08160-70001 2 Horn (low) F-1 L66 X 1 Intermediate connector O-3 Z02 DT-T 2 Diode
F03 DT-T 3 Bucket positioner proximity switch A-2 L67 DT-T 12 Intermediate connector W-9
F04 DT-T 3 Lift arm positioner proximity switch D-1 L68 DT-T 2 Resistor O-7
F07 DT-T 2 ECSS solenoid valve E-1 L69 SWP 6 Auto reversible fan switch Q-9
F07A DT-T 2 Diode E-1 L70 SWP 8 Speed range select resistor O-9
F10 Terminal 1 GND (front frame) E-1 L71 DT-T 4 Intermediate connector W-2
SEN03094-01
WA200-6
23
WA200-6 25
SEN03094-01

©2007 KOMATSU
All Rights Reserved
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Shop Manual Komatsu WA200-6

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Shop Manual Komatsu WA200-6

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SEN03081-02

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

WA200-6 70001 and up

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN03081-02

00 Index and foreword SEN03082-02

10 Structure, function and maintenance standard SEN03084-00

20 Standard value table SEN03085-00

30 Testing and adjusting SEN03086-00

Troubleshooting by failure code (Display of code), Part 4 SEN03740-00

50 Disassembly and assembly SEN03088-00

90 Diagrams and drawings SEN03089-01

00 Index and foreword

10 Structure, function and maintenance standard

Brake system SEN03253-00

20 Standard value table

30 Testing and adjusting

Testing and adjusting, Part 3 SEN03734-00

Troubleshooting by failure code (Display of code), Part 3 SEN03739-00

E-17 Air conditioner does not operate or stop............................................................................. 70

50 Disassembly and assembly

Sketches of special tools............................................................................................................. 11

90 Diagrams and drawings

WA200-6 Wheel loader

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

WA200-6 70001 and up

00 Index and foreword 1

Safety notice 1 (Rev. 2007/03)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-