These Komatsu WA800-3E0 and WA900-3E0 wheel loaders are big quarry and mine loaders, moving rock, ore, and overburden all day. The Komatsu WA800-3E0, WA900-3E0 Wheel Loader Shop Manual (SEN02034-28) is what shops and field techs reach for when a machine is down or coming in for major service. People buying this kind of manual usually want step‑by‑step repair info, not just “where’s the switch” basics. If you’re trying to keep these loaders earning instead of parked, this is the level of book you’re looking at.
What this manual helps you do
- Trace hydraulic and electrical faults using system layouts and step‑by‑step diagnostic logic that these machines typically require.
- Check and adjust engine, drivetrain, and brake systems the way Komatsu expects, so you don’t repeat common student mistakes like skipping re‑checks after adjustments.
- Follow disassembly and reassembly sequences for major components, so you don’t damage expensive castings or trap parts behind others.
- Diagnose performance issues in the powertrain and hydraulic circuits by comparing expected behavior to what you’re actually seeing in the field.
- Handle major rebuild work in a shop setting, from pulling components to final verification tests before the loader goes back to production.
Who this is for
This is aimed at shop mechanics, field service techs, and trainers working on WA800-3E0 or WA900-3E0 loaders. Operators or fleet managers wanting daily checks and basic maintenance are usually better off with the Operation and Maintenance Manual instead of this shop manual.
FAQ
Q: Is this a PDF I can search and print?
A: Yes, it’s a PDF, so you can search by keyword and print the sections you need for the bay or field.
Q: Does it go deep enough for full overhauls?
A: Yes, the Shop Manual for Komatsu WA800-3E0, WA900-3E0 Wheel Loader walks through diagnostic procedures, disassembly sequences, and reference data used during workshop‑level repairs.
Q: How do I know it matches my exact machine?
A: You should match your loader’s model designation and use the book reference SEN02034-28; if your tag doesn’t match those, you may need a different manual issue.
If you’re repairing or diagnosing WA800-3E0 or WA900-3E0 loaders, this is more or less the right book. If you only need operating tips or basic service intervals, keep looking for the operation/maintenance manual instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- Index
- Composition of shop manual
- Table of contents
- Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
- 01 Specification
- Specification and technical data
- General assembly drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
- 10 Structure, function and maintenance standard
- Engine and cooling system
- Engine mount
- Transmission mount
- Damper
- Radiator, oil cooler, aftercooler
- Fuel system
- Power train, Part 1
- Power train
- Power train system
- Torque converter
- Torque converter regulator valve
- Transmission
- Transfer
- Transmission control valve
- Power train, Part 2
- Torque converter oil cooler
- Drive shaft
- Center support
- Axle
- Differential
- Final drive
- Steering system
- Steering piping
- AJSS lever linkage
- EPC valve
- Steering column
- Rotary valve
- Steering control valve
- Steering unit (orbit-roll valve)
- Steering pump
- Steering cylinder
- Slow return valve
- Emergency steering piping
- Diverter valve
- Emergency steering pump
- Brake system
- Brake piping
- Brake
- Brake valve
- Accumulator charge valve
- PPC relief valve
- Accumulator (for brake)
- Slack adjuster
- Parking brake
- Parking brake caliper
- Spring cylinder
- Parking brake solenoid
- Brake cooling system (if equipped)
- Brake cooling system (55°C specification) (If equipped)
- Undercarriage and frame
- Axle mount
- Center hinge pin
- Tire and wheel
- Jack up point
- Hydraulic system, Part 1
- Hydraulic piping
- Work equipment lever linkage
- Hydraulic tank
- Torque conbverter charging, PPC and brake pump
- Hydraulic system, Part 2
- Main control valve
- Accumulator (For PPC valve)
- Main piston pump
- Main piston pump cut-off solenoid valve
- PPC valve
- PPC relief valve
- Switch pump
- Control pump
- Work equipment
- Work equipment linkage
- Bucket positioner and lift arm kick-out
- Remote lift arm positioner
- Auto greasing system
- Hydraulic cylinder
- Cab and its attachments
- Electrical system, Part 1
- Machine monitor system
- Main monitor
- Maintenance monitor
- Electrical system, Part 2
- Work equipment control system
- Remote position, joystick steering controller
- Active power maximizing electrical circuit
- Automatic transmission system (ATM)
- Electrical system, Part 3
- Engine starting/stopping circuit
- Parking brake circuit
- Preheating circuit
- Emergency engine stop
- Hydraulic oil level sensor
- Battery and starting motor disconnector switch and starting aid connector
- Sensor
- 20 Standard value table
- Standard service value table
- Standard value table for engine
- Standard value table for chassis
- Standard value table for electrical system
- 30 Testing and adjusting
- Testing and adjusting, Part 1
- Precautions before work
- Tools for testing, adjusting, and troubleshooting
- Measuring engine speed
- Measuring intake air (boost) pressure
- Measuring exhaust gas color
- Measuring exhaust temperature
- Adjusting valve clearance
- Measuring compression pressure
- Measuring blow-by pressure
- Measuring engine oil pressure
- Handling fuel system equipment
- Releasing residual pressure in fuel system
- Testing fuel pressure
- Measuring fuel return rate and leakage
- Bleeding air from fuel circuit
- Testing leakage in fuel system
- Handling reduced cylinder mode operation
- Handling no-injection cranking operation
- Handling controller voltage circuit
- Adjusting speed sensor
- Testing and adjusting alternator belt tension
- Testing and adjusting belt tension for air conditioner compressor
- Testing of upper drive shaft sliding part
- Testing and adjusting power train oil pressure
- Procedure for operating emergency steering spool when transmission valve fails
- Testing and adjusting, Part 2
- Measuring operating effort of AJSS lever (AJSS specification)
- Testing and adjusting AJSS lever angle sensor and frame angle sensor (AJSS specification)
- Testing and adjusting steering stopper bolt (AJSS specification)
- Testing and adjusting steering stop valve
- Measuring steering oil pressure
- Testing and adjusting emergency steering oil pressure
- Bleeding air from steering circuit
- Measuring brake pedal
- Measuring brake performance
- Testing and adjusting accumulator charge pressure
- Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
- Measuring wheel brake oil pressure reduction
- Measuring wear of wheel brake disc
- Bleeding air from wheel brake circuit
- Releasing residual pressure in brake accumulator circuit
- Testing parking brake performance
- Measuring parking brake solenoid oil pressure
- Testing and adjusting wear of parking brake pad
- Testing and adjusting PPC oil pressure
- Adjusting PPC valve linkage
- Testing and adjusting work equipment oil pressure
- Bleeding air from piston pump
- Bleeding air from work equipment circuit
- Adjusting work equipment lever linkage
- Releasing remaining pressure in hydraulic circuit
- Testing and adjusting bucket proximity switch
- Testing and adjusting bucket positioner and tilt limiter
- Testing and adjusting lift arm proximity switch
- Testing and adjusting active working proximity switch
- Checking proximity switch operation pilot lamp
- Testing and adjusting lift arm position detection lever
- Adjusting speedometer module of main monitor
- Testing and adjusting, Part 3
- Special function of engine service monitor
- VHMS controller initial setting procedure
- Precautions for replacing VHMS controller
- Pm-clinic inspection table
- 40 Troubleshooting
- Failure code table and fuse locations
- Failure code table
- Method of displaying action code and failure code on machine monitor
- Transmission & AJSS controller LED display
- Transmission control system
- AJSS (Advanced Joystick Steering System) control system
- Location of fuse
- Location of relay
- General information on troubleshooting
- Precautions before work
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Checking water pump for water leakage
- Classification and procedures of troubleshooting
- Contents of troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- Troubleshooting by failure code (Display of code), Part 1
- Failure code [15B0NX] (Transmission oil filter: Clogging)
- Failure code [AA1ANX] (Air cleaner L.H: Clogged)
- Failure code [AA1BNX] (Air cleaner R.H: Clogged)
- Failure code [AB00L4] (Alternator: Failure on battery charge circuit (Rterminal signal is present and engine is stopped)
- Failure code [AB00L6] (Alternator: Failure on battery charge circuit (Rterminal signal is present and engine is stopped)
- Failure code [AB00MA] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)
- Failure code [AB00MB] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)
- Failure code [AB00MC] (Alternator: Failure on battery charge circuit (Absence of R terminal signal and detection error)
- Failure code [B@BAZK] (Engine oil: Oil level low)
- Failure code [B@BAZG] (Engine oil: Low oil pressure)
- Failure code [B@BCZK] and [b@BCZK] (Radiator coolant: Low coolant level)
- Failure code [B@BDNS] (Engine: Overheating)
- Failure code [B@C6NS] (Front brake oil temperature: Overheating)
- Failure code [B@CENS] (Torque converter oil temperature overheating)
- Failure code [B@JFZG] (Brake oil: Low oil pressure)
- Troubleshooting by failure code (Display of code), Part 2
- Failure code [CA111] Engine controller (Left bank): Internal abnormality
- Failure code [CB111] Engine controller (Right bank): Internal abnormality
- Failure code [CA115] Abnormal engine Ne and Bkup speed sensors (At left bank): Abnormal speed sensor signal
- Failure code [CB115] Abnormal engine Ne and Bkup speed sensors (At right bank): Abnormal speed sensor signal
- Failure code [CA122] Charge pressure sensor too high (At left bank only): Excessively high voltage detected
- Failure code [CA123] Charge pressure sensor too low (At left bank only): Excessively low voltage detected
- Failure code [CA131] Throttle sensor abnormally high level (Only left bank): High voltage detection
- Failure code [CA132] Throttle sensor too low (At left bank only): Excessively low voltage detected
- Failure code [CA135] Oil pressure sensor too high (At left bank only): Excessively high voltage detected
- Failure code [CA141] Oil pressure sensor too low (At left bank only): Excessively low voltage detected
- Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected
- Failure code [CA145] Coolant temperature sensor too low (At left bank only): Excessively low voltage detected
- Failure code [CA153] Charge temperature sensor too high (At left bank only): Excessively high voltage detected
- Failure code [CA154] Charge temperature sensor too low (At left bank only): Excessively low voltage detected
- Failure code [CA187] Sensor power supply (2) abnormally low level (Left bank): Low voltage detection
- Failure code [CB187] Sensor power supply (2) abnormally low level (Right bank): Low voltage detection
- Failure code [CA212] Engine oil temperature sensor abnormally high level (Only left bank): High voltage detection
- Failure code [CA213] Engine oil temperature sensor abnormally low level (Only left bank): Low voltage detection
- Failure code [CA221] Atmospheric pressure sensor too high (At left bank only): Excessively high voltage detected
- Failure code [CA222] Atmospheric pressure sensor too low (At left bank only): Excessively low voltage detected
- Failure code [CA227] Sensor power source (2) too high (At left bank): Excessively high voltage detected
- Failure code [CB227] Sensor power supply (2) abnormally high level (Right bank): High voltage detection
- Failure code [CA234] Engine over speed (At left bank only): Excessively high speed
- Failure code [CA238] Abnormal power source for Ne speed sensor (At left bank only): Excessively low voltage detected
- Failure code [CB238] Abnormal power source for Ne speed sensor (At right bank only): Excessively low voltage detected
- Failure code [CA263] Fuel temperature sensor too high (At left bank): Excessively high voltage detected
- Failure code [CB263] Fuel temperature sensor too high (At right bank): Excessively high voltage detected
- Failure code [CA265] Fuel temperature sensor abnormally low level (Left bank): Low voltage detection
- Failure code [CB265] Fuel temperature sensor abnormally low level (Right bank): Low voltage detection
- Failure code [CA271] PCV1 short circuit (Left bank): Short circuit
- Failure code [CB271] PCV1 short circuit (Right bank): Short circuit
- Failure code [CA272] PCV1 disconnection (Left bank): Disconnection
- Failure code [CB272] PCV1 disconnection (Right bank): Disconnection
- Failure code [CA273] PCV2 short circuit (Left bank): Short circuit
- Failure code [CB273] PCV2 short circuit (Right bank): Short circuit
- Failure code [CA274] PCV2 disconnection (Left bank): Disconnection
- Failure code [CB274] PCV2 disconnection (Right bank): Disconnection
- Troubleshooting by failure code (Display of code), Part 3
- Failure code [CA322] Injector No. 1 (L/B No.1) system disconnection or short circuit (At left bank): Disconnection, short circuit
- Failure code [CA323] Injector No. 5 (L/B No.5) system disconnection or short circuit (At left bank): Disconnection, short circuit
- Failure code [CA324] Injector No. 3 (L/B No.3) system disconnection or short circuit (At left bank): Disconnection, short circuit
- Failure code [CA325] Injector No. 6 (L/B No.6) system disconnection or short circuit (At left bank): Disconnection, short circuit
- Failure code [CA331] Injector No. 2 (L/B No.2) system disconnection or short circuit (At left bank): Disconnection, short circuit
- Failure code [CA332] Injector No. 4 (L/B No.4) system disconnection or short circuit (At left bank): Disconnection, short circuit
- Failure code [CA342] Engine controller data mismatch (Left bank): Mismatch
- Failure code [CB342] Engine controller data mismatch (Right bank): Mismatch
- Failure code [CA351] Abnormal injector drive circuit (At left bank): Abnormal circuit
- Failure code [CB351] Injector drive circuit abnormality (Right bank): Circuit abnormality
- Failure code [CA352] Sensor power supply (1) abnormally low level (Left bank): Low voltage detection
- Failure code [CB352] Sensor power supply (1) abnormally low level (Right bank): Low voltage detection
- Failure code [CA386] Sensor power supply (1) abnormally high level (Left bank): High voltage detection
- Failure code [CB386] Sensor power supply (1) abnormally high level (Right bank): High voltage detection
- Failure code [CA431] Trouble in idle validation switch
- Failure code [CA432] Idle validation action error
- Failure code [CA441] Power supply voltage abnormally low level (Left bank): Low voltage detection
- Failure code [CB441] Power supply voltage abnormally low level (Right bank): Low voltage detection
- Failure code [CA442] Power supply voltage abnormally high level (Left bank): High voltage detection
- Failure code [CB442] Power supply voltage abnormally high level (Right bank): High voltage detection
- Failure code [CA449] Common rail abnormally high pressure (2) (Left bank): Abnormally high pressure occurrence
- Failure code [CB449] Common rail abnormally high pressure (2) (Right bank): Abnormally high pressure occurrence
- Failure code [CA451] Common rail pressure sensor too high (At left bank): Excessively high voltage detected
- Failure code [CB451] Common rail pressure sensor abnormally high level (Right bank): High voltage detection
- Failure code [CA452] Common rail pressure sensor abnormally low level (Left bank): Abnormally low voltage detection
- Failure code [CB452] Common rail pressure sensor abnormally low level (Right bank): Abnormally low voltage detection
- Failure code [CA553] Common rail pressure too high (1) (At left bank): Excessively high pressure detected
- Failure code [CB553] Common rail pressure too high (1) (At right bank): Excessively high pressure detected
- Failure code [CA554] In-range error in common rail pressure sensor (At left bank): In-range error
- Failure code [CB554] In-range error in common rail pressure sensor (At right bank): In-range error
- Failure code [CA559] Loss of pressure feed from supply pump (1) (At left bank): Loss of pressure feed detected
- Failure code [CB559] Loss of pressure feed from supply pump (1) (At right bank): Loss of pressure feed detected
- Failure code [CA689] Abnormal engine Ne speed sensor (At left bank): Abnormal signal
- Failure code [CB689] Abnormal engine Ne speed sensor (At right bank): Abnormal signal
- Failure code [CA691] Intake air temperature sensor abnormally high level (Only left bank): High voltage detection
- Failure code [CA692] Intake air temperature sensor abnormally low level (Only left bank): Low voltage detection
- Failure code [CA731] Abnormal engine Bkup speed sensor phase (At left bank): Abnormal phase
- Failure code [CB731] Abnormal engine Bkup speed sensor phase (At right bank): Abnormal phase
- Troubleshooting by failure code (Display of code), Part 4
- Failure code [CA757] Loss of all engine controller data (At left bank): Loss of all data
- Failure code [CB757] Loss of all engine controller data (At right bank): Loss of all data
- Failure code [CA778] Engine Bkup speed sensor abnormality (At left bank): Bkup signal error
- Failure code [CB778] Engine Bkup speed sensor abnormality (Right bank): Bkup signal error
- Failure code [CA781] Inter-multicontroller communication error (Left bank): Communication error
- Failure code [CB781] Inter-multicontroller communication error (Right bank): Communication error
- Failure code [CA1257] Multicontroller distinction wiring harness key error (Left bank): Distinction error
- Failure code [CB1257] Multicontroller distinction wiring harness key error (Right bank): Distinction error
- Failure code [CB1548] Injector #7 (R/B #1) system disconnection/short circuit (Right bank): Disconnection/Short circuit
- Failure code [CB1549] Injector #8 (R/B #2) system disconnection/short circuit (Right bank): Disconnection/Short circuit
- Failure code [CB1551] Injector #10 (R/B #4) system disconnection/short circuit (Right bank): Disconnection/Short circuit
- Failure code [CB1552] Injector #11 (R/B #5) system disconnection/short circuit (Right bank): Disconnection/Short circuit
- Failure code [CB1553] Injector #12 (R/B #6) system disconnection/short circuit (Right bank): Disconnection/Short circuit
- Failure code [CB1622] Injector #9 (R/B #3) system disconnection/short circuit (Right bank): Disconnection/Short circuit
- Failure code [CA1633] KOMNET abnormality (Left bank): Communication error
- Failure code [CA2185] Throttle sensor power supply abnormally high level (Only left bank): High voltage detection
- Failure code [CA2186] Throttle sensor power source too low (At left bank only): Excessively low voltage detected
- Failure code [CA2249] Loss of pressure feed from supply pump (2) (At left bank): Loss of pressure feed detected
- Failure code [CB2249] Loss of pressure feed from supply pump (2) (At right bank): Loss of pressure feed detected
- Failure code [CA2555] Intake heater relay voltage low error (Left bank only)
- Failure code [CA2556] Intake heater relay voltage high error (Left bank only)
- Failure code [D160KZ] (or TM & AJSS controller LED display [10], abnormality in backup lamp relay system: Disconnection, short circuit or hot short circuit
- Failure code [D180KA] (Preheating relay output system: Disconnection)
- Failure code [D180KB] (Preheating relay output system: Grounding fault)
- Failure code [D180KY] (Preheating relay output system: Hot short circuit)
- Failure code [D19AKB] (or TM & AJSS controller LED display [56], abnormality in joystick caution relay output system: Disconnection or short circuit)
- Failure code [D19BKZ] (or TM & AJSS controller LED display [62], abnormality in joystick neutral interlock relay output system: Disconnection or short circuit)
- Failure code [D1EFKA] (Pre-lubrication start relay output system: Disconnection)
- Failure code [D1EFKB] (Pre-lubrication start relay output system: Grounding fault)
- Failure code [D1EFKY] (Pre-lubrication start relay output system: Hot short circuit)
- Failure code [D1EHKA] (Engine start relay output system: Disconnection)
- Failure code [D1EHKB] (Engine start relay output system: Grounding fault)
- Failure code [D1EHKY] (Engine start relay output system: Hot short circuit)
- Failure code [D5ZHL6] (Starting switch terminal C signal: Error)
- Failure code [D5ZSKA] (Machine monitor communication output: Disconnection)
- Failure code [D5ZSKB] (Machine monitor communication output: Grounding fault)
- Failure code [D5ZSKY] (Machine monitor communication output: Hot short circuit)
- Troubleshooting by failure code (Display of code), Part 5
- Failure code [DB2RKR] (Engine controller CAN-NET communication: Disconnection and grounding fault)
- Failure code [DBB0KK] (or VHMS LED display: "n9" → "01", VHMS controller: Low supply voltage)
- Failure code [DBB0KQ] (or VHMS LED display: "nF" → "11", VHMS controller model selection: Disagreement of model selection signals)
- Failure code [DBB3KK] (or VHMS LED display: "n9" → "05", VHMS controller: Low direct supply voltage)
- Failure code [DBB5KP] (or VHMS LED display: "n9" → "04", VHMS controller sensor power supply (5 V): Low output voltage)
- Failure code [DBB6KP] (or VHMS LED display: "n9" → "02", VHMS controller sensor power supply (24 V): Low output voltage)
- Failure code [DBBQKR] (or VHMS LED display: "n8" → "02", VHMS controller CAN communication abnormality)
- Failure code [DBG2KK] (Solenoid power supply: Low voltage)
- Failure code [DBG3KK] (Battery direct power supply: Low voltage)
- Failure code [DBG9KQ] (Model selection signal: Abnormal)
- Failure code [DBGRKR] (Pre-lubrication controller CAN-NET communication: Disconnection or grounding fault)
- Failure code [DBL0KR] (Power ladder controller CAN-NET communication: Disconnection or grounding fault)
- Failure code [DDE2KB] (Engine oil pressure switch error: Grounding fault)
- Failure code [DDE2L6] (Engine oil pressure switch error: Disconnection or hot short circuit)
- Failure code [DDK3KZ] (or TM & AJSS controller LED display [20], abnormality in joystick forward-reverse switch system: Disconnection or hot short circuit)
- Failure code [DDK5KZ] (or TM & AJSS controller LED display: “21”, Abnormality in shifting up/down switch system: Disconnection, short circuit or hot short circuit)
- Failure code [DDP5KZ] (Abnormality in steering lock switch system: Disconnection or short circuit)
- Failure code [DGE5KX] (Atmospheric temperature sensor: Out of input signal range (short))
- Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range (short))
- Failure code [DGR4KX] (Front brake oil temperature sensor: Out of input signal range (short))
- Troubleshooting by failure code (Display of code), Part 6
- Failure code [DGT5KA] (or VHMS LED display: "n3" o "12", L.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit)
- Failure code [dGT5KA] (or VHMS LED display: "n3" o "22", L.H. bank exhaust gas temperature sensor system (Rear): Disconnection or short circuit)
- Failure code [DGT5KB] (or VHMS LED display: "n3" o "11", L.H. bank exhaust gas temperature sensor system (Front): Hot short circuit)
- Failure code [dGT5KB] (or VHMS LED display: "n3" o "21", L.H. bank exhaust gas temperature sensor system (Rear): Hot short circuit)
- Failure code [DGT6KA] (or VHMS LED display: "n3" o "24", R.H. bank exhaust gas temperature sensor system (Front): Disconnection or short circuit)
- Failure code [dGT6KA] (or VHMS LED display: "n3" o "26", R.H. exhaust gas temperature sensor system (Rear): Disconnection or short circuit)
- Failure code [DGT6KB] (or VHMS LED display "n3" o "23", R.H. bank exhaust gas temperature sensor system (front): Hot short circuit)
- Failure code [dGT6KB] (or VHMS LED display "n3" o "25", R.H. bank exhaust gas temperature sensor system (rear): Hot short circuit)
- Failure code [DHE5KB] (or VHMS_LED display: "n3" o "32", Blow-by pressure sensor system: Short circuit)
- Failure code [DHE5KY] (or VHMS LED display: "n3" o "31", Blow-by pressure sensor system: Hot short circuit)
- Failure code [DHP2KX] (Main pump oil pressure sensor error: Disconnection or short circuit)
- Failure code [DHT3KX] (or VHMS LED display: "n6" o "14", Transmission oil pressure sensor system: Out of input signal range)
- Failure code [DHT8KX] (Steering pump oil pressure sensor error): Disconnection or short circuit)
- Failure code [DHU2KX] (Front brake oil pressure sensor error: Disconnection or short circuit)
- Failure code [DHU3KX] (Rear brake oil pressure sensor error: Disconnection or short circuit)
- Failure code [DK00L8] (or TM & AJSS controller LED display [58], steering and frame angle displacement)
- Failure code [DK30KX] (or TM & AJSS controller LED display [57], abnormality in steering angle potentiometer system): Disconnection or short circuit)
- Failure code [DKD0KX] (or TM & AJSS controller LED display [59], abnormality in frame angle potentiometer system: Disconnection or short circuit)
- Failure code [DLE4KA] (or TM & AJSS controller LED display [23], abnormality in engine speed sensor system: Disconnection, short circuit or hot short circuit)
- Failure code [DLT4KA] (or TM & AJSS controller LED display [22], abnormality in speed sensor system: Disconnection, short circuit or hot short circuit)
- Failure code [DUM7KY] (Pre-lubrication operation lamp output abnormality: Hot short circuit)
- Failure code [DUM7KZ] (Pre-lubrication operation lamp output abnormality: Disconnection or grounding fault)
- Failure code [DXF0KZ] (or TM & AJSS controller LED display [63], abnormality in joystick EPC solenoid system: Disconnection, short circuit or hot short circuit)
- Failure code [DXH4KZ] (or TM & AJSS controller LED display [14], abnormality in 1st solenoid system: Disconnection, short circuit or hot short circuit)
- Failure code [DXH5KZ] (or TM & AJSS controller LED display [15], abnormality in 2nd solenoid system: Disconnection, short circuit or hot short circuit)
- Failure code [DXH6KZ] (or TM & AJSS controller LED display [16], abnormality in 3rd solenoid system: Disconnection, short circuit or hot short circuit)
- Failure code [DXH7KZ] (or TM & AJSS controller LED display [13], abnormality in R solenoid system: Disconnection, short circuit or hot short circuit)
- Failure code [DXH8KZ] (or TM & AJSS controller LED display [12], abnormality in F solenoid system: Disconnection, short circuit or hot short circuit)
- Failure code [F@BBZL] (or VHMS LED display: "n3" o "38", Blow-by pressure sensor system: High pressure error)
- Failure code [F@BYNR] (or VHMS LED display: "n3" o "62", L.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)
- Failure code [f@BYNR] (or VHMS LED display: "n3" o "72", L.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)
- Failure code [F@BYNS] (or VHMS LED display: "n3" o "61", L.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)
- Failure code [f@BYNS] (or VHMS LED display: "n3" o "71", L.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)
- Failure code [F@BZNR] (or VHMS LED display: "n3" o "82", R.H. front exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)
- Failure code [f@BZNR] (or VHMS LED display: "n3" o "92", R.H. rear exhaust gas temperature sensor (2): Abnormal rise of exhaust gas temperature)
- Failure code [F@BZNS] (or VHMS LED display: "n3" o "38", R.H. front exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)
- Failure code [f@BZNS] (or VHMS LED display: "n3" o "39", R.H. rear exhaust gas temperature sensor (1): Abnormal rise of exhaust gas temperature)
- Troubleshooting of electrical system (E-mode)
- E-1 Engine does not start
- E-2 Abnormality in preheating system
- E-3 Transmission and AJSS controller does not work
- E-4 Transmission and AJSS controller model selection error
- E-5 Parking brake does not work (as the emergency brake)
- E-6 Parking brake is applied while machine is traveling
- E-7 Parking brake is released as starting switch is turned ON
- E-8 Setting to the neutral position becomes unavailable while the parking brake is in operation (parking brake operates normally)
- E-9 Parking brake remains in the neutral and not removable to other position (when parking brake is not applied)
- E-10 Defective kick-down switch
- E-11 Defective hold switch
- E-12 Lift arm (boom) kick-out is unavailable
- E-13 Bucket positioner functional error
- E-14 Active working functional error
- E-15 Turn signal or hazard display do not flash
- E-16 Small lamp does not light up
- E-17 Head lamp does not light up
- E-18 Abnormality in lighting up of front working lamp
- E-19 Abnormality in lighting up of rear working lamp
- E-20 Abnormality in transmission cut-off
- E-21 Abnormality in low idle selection
- E-22 Abnormality in parking brake dragging warning
- E-23 Abnormality in buzzer
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Method of using troubleshooting chart
- H-1 Machine does not move
- H-2 Machine lacks power or speed (every speed range)
- H-3 Excessive time lag when starting machine or shifting gear
- H-4 Torque converter oil temperature is high
- H-5 Steering does not turn
- H-6 Turning, response of steering is poor
- H-7 Joystick lever is heavy
- H-8 Steering wheel shakes or jerks
- H-9 Minimum turning radii to right and left are different
- H-10 Wheel brakes do not work or braking effect is poor
- H-11 Wheel brakes are not released or brakes drag
- H-12 Lift arm does not rise
- H-13 Lift arm moves slowly or does not have sufficient lifting power
- H-14 When raising lift arm, becomes slow at certain height
- H-15 Lift arm cylinder cannot hold down bucket
- H-16 Lift arm has large amount of hydraulic drift
- H-17 Lift arm fluctuates while working
- H-18 Lift arm drops momentarily when lever is operated from HOLD to RAISE
- H-19 Bucket does not tilt back
- H-20 Bucket moves slowly or has insufficient tilt back power
- H-21 Bucket movement becomes slow during tilt back
- H-22 Bucket cylinder cannot hold down bucket
- H-23 Bucket has large amount of hydraulic drift
- H-24 Bucket fluctuates while traveling under load (work equipment valve "HOLD")
- H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT
- H-26 Lift arm and bucket levers do not move smoothly
- Troubleshooting of engine (S-mode)
- Method of using troubleshooting chart
- S-1 Starting performance is poor
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly
- S-6 Engine lacks output (or lacks power)
- S-7 Exhaust smoke is black (incomplete combustion)
- S-8 Oil consumption is excessive (or exhaust smoke is blue)
- S-9 Oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
- S-12 Oil pressure drops
- S-13 Oil level rises (Entry of coolant or fuel)
- S-14 Coolant temperature becomes too high (overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
- Troubleshooting of machine monitor system (M-mode)
- Machine monitor system
- M-1 Machine monitor does not work
- M-2 Engine starts immediately after (within 3 sec of) turning starting switch ON, but all the machine monitors remain lit
- M-3 Speedometer display does not work
- M-4 Shift indicator error
- M-5 Monitor turn signal (hazard) indicator does not light up
- M-6 Parking indication error
- M-7 Abnormality in preheating system
- M-8 Night lamp does not light up
- M-9 Front work lamp error
- M-10 Rear work lamp error
- M-11 Abnormality in transmission cut-off switch
- M-12 Abnormality in low idle selection
- M-13 Emergency steering indication error
- M-14 Parking brake dragging warning error
- M-15 Buzzer and caution lamp error upon parking brake dragging warning outputting
- M-16 Buzzer error
- M-17 Switching state of machine monitor is not stored
- M-18 Failure indication mode error
- M-19 Machine monitor does not indicate failure code
- M-20 Abnormality in auto grease system
- Troubleshooting of maintenance monitor system (K-mode)
- Maintenance monitor system
- K-1 Maintenance monitor does not work
- K-2 Immediately after turning starting switch ON (within 3 sec.), engine starts but the maintenance monitor remains fully lit up
- K-3 Work check item flashes upon turning starting switch ON (engine not running)
- K-4 Caution item flashes upon turning starting switch ON (engine running)
- K-5 The warning buzzer does not sound while caution item indicator flashes
- K-6 The warning buzzer sounds while monitor indicates no error
- K-7 The warning lamps (check lamp and caution lamp) do not flash while caution item indicator flashes
- K-8 Warning lamps (check and caution lamps) lights up while the maintenance monitor indicates no error
- K-9 Night lamp does not light up
- K-10 Night lamp remains lit up
- K-11 Service meter does not work
- K-12 Service meter keeps on working (when engine stops)
- K-13 Gauge items (fuel, engine coolant temperature and torque converter oil temperature) error
- Troubleshooting of remote boom positioner controller system (if equipped) (W-mode)
- W-1 Short circuit, disconnection in dumping solenoid system
- W-2 Short circuit in power source at hot end of dumping solenoid
- W-3 Short circuit in power source at return end of dumping solenoid
- W-4 Boom kick-out function trouble
- W-5 Disconnection in boom RAISE, LOWER detection pressure switch
- W-6 Short circuit, disconnection in boom angle potentiometer system
- W-7 Sensor cannot be adjusted
- W-8 Abnormality in engine speed signal system
- W-9 Remote positioner RAISE, LOWER LEDs do not light up
- W-10 Remote positioner RAISE set LED does not flash
- W-11 Remote positioner LOWER set LED does not flash
- W-12 Buzzer for switch operation does not sound
- W-13 Shock when stopping boom
- W-14 Short circuit in boom RAISE, LOWER pressure detection switch
- 50 Disassembly and assembly
- General information on disassembly and assembly
- Precautions before work
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Engine and cooling system, Part 1
- Removal and installation of engine assembly
- Removal and installation of radiator assembly
- Removal and installation of damper assembly
- Disassembly and assembly of damper assembly
- Removal and installation of fuel tank assembly
- Engine and cooling system, Part 2
- Removal and installation of right bank fuel supply pump assembly
- Removal and installation of left bank fuel supply pump assembly
- Removal and installation of cylinder head assembly
- Removal and installation of fuel injector assembly
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Power train, Part 1
- Disassembly and assembly of transfer assembly
- Disassembly and assembly of PTO assembly
- Removal and installation of parking brake calipers assembly
- Disassembly and assembly of parking brake calipers assembly
- Removal and installation of parking brake pad
- Removal and installation of parking brake spring cylinder
- Removal and installation of torque converter and transmission assembly
- Power train, Part 2
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of transmission assembly
- Power train, Part 3
- Removal and installation of front axle assembly
- Removal and installation of rear axle assembly
- Removal and installation of center support assembly
- Disassembly and assembly of center support assembly
- Removal and installation of differential assembly
- Disassembly and assembly of differential assembly
- Disassembly and assembly of final drive assembly
- Brake system
- Removal and installation of brake assembly
- Disassembly and assembly of brake assembly
- Removal and installation of left brake valve assembly
- Removal and installation of right brake valve assembly
- Disassembly and assembly of accumulator charge valve
- Disassembly and assembly of slack adjuster
- Undercarriage and frame
- Removal and installation of center hinge pin
- Removal and installation of counterweight assembly
- Hydraulic system
- Removal and installation of hydraulic tank and filter case assembly
- Removal and installation of hydraulic pump assembly
- Removal and installation of work equipment control valve assembly
- Disassembly and assembly of work equipment control valve assembly
- Disassembly and assembly of PPC valve assembly
- Removal and installation of steering valve assembly
- Removal and installation of diverter valve assembly
- Disassembly and assembly of diverter valve assembly
- Removal and installation of Orbit-roll assembly
- Removal of steering stop valve
- Installtion of steering stop valve
- Disassembly and assembly of hydraulic cylinder assembly
- Work equipment
- Removal and installation of work equipment assembly
- Replacement of boom front bushing
- Cab and its attachments
- Removal and installation of operator cab assembly
- Removal and installation of floor frame assembly
- Disassembly and assembly of operator’s seat assembly
- Removal and installation of AJSS lever switch assembly
- Electrical system
- Removal and installation of engine controller assembly
- Removal and installation of transmission and steering controller assembly
- Removal and installation of main monitor assembly
- Removal and installation of air conditioner unit assembly
- 90 Diagrams and drawings
- Hydraulic diagrams and drawings
- Power train hydraulic circuit diagram
- Brake hydraulic circuit diagram
- Work equipment hydraulic circuit diagram
- Electrical diagrams and drawings
- Electrical circuit diagram (1/8)
- Electrical circuit diagram (2/8)
- Electrical circuit diagram (3/8)
- Electrical circuit diagram (4/8)
- Electrical circuit diagram (5/8) (STD)
- Electrical circuit diagram (5/8) (NA specification)
- Electrical circuit diagram (6/8)
- Electrical circuit diagram (7/8)
- Electrical circuit diagram (8/8)
- Electrical circuit diagram of emergency engine stop
- Electrical circuit diagram of hydraulic oil level sensor
- Electrical circuit diagram for KAL (1/2)
- Electrical circuit diagram for KAL (2/2)
- Electrical circuit diagram of battery and starting motor disconnector switch and starting aid connector
- Electrical circuit diagram for bucket tilt limitter (If equipped)
- Electrical circuit diagram for auto grease system (if equipped)
- Connector arrangement diagram
Komatsu
