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KOMATSU WA200-5 WA200PT-5 SHOP MANUAL SEBM0333-10 – PDF DOWNLOAD
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Description
KOMATSU WA200-5 WA200PT-5 SHOP MANUAL SEBM0333-10 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA200-5 WA200PT-5 SHOP MANUAL SEBM0333-10 – PDF DOWNLOAD
Language : English
Pages : 818
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA200-5 WA200PT-5 SHOP MANUAL SEBM0333-10 – PDF DOWNLOAD
COVER ...................................................................................................................................................... 1 CONTENTS.................................................................................................................................................... 2 LIST OF REVISED PAGES....................................................................................................................................... 3 01 GENERAL.................................................................................................................................................. 29 GENERAL ASSEMBLY DRAWINGS............................................................................................................................... 30 SPECIFICATIONS.......................................................................................................................................... 31 WEIGHT TABLE............................................................................................................................................ 35 LIST OF LUBRICANT AND COOLANT........................................................................................................................... 37 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD.............................................................................................................. 39 ENGINE MOUNT AND TRANSFER MOUNT......................................................................................................................... 40 DAMPER ................................................................................................................................................. 41 COOLING SYSTEM ......................................................................................................................................... 42 TRANSFER OIL COOLER..................................................................................................................................... 43 POWER TRAIN............................................................................................................................................. 46 POWER TRAIN SYSTEM DIAGRAM.............................................................................................................................. 48 DRIVE SHAFT(PROPELLER SHAFT)............................................................................................................................ 50 HST HYDRAULIC PIPING DIAGRAM............................................................................................................................ 51 HST PUMP................................................................................................................................................ 52 HIGH-PRESSURE RELIEF VALVE.............................................................................................................................. 54 LOW-PRESSURE RELIEF VALVE............................................................................................................................... 56 HST CHARGE PUMP......................................................................................................................................... 57 SPEED-RELATED VALVE(DA VALVE)........................................................................................................................... 58 HIGH-PRESSURE CUT-OFF VALVE............................................................................................................................. 59 HST MOTOR............................................................................................................................................... 60 EP SERVO VALVE.......................................................................................................................................... 63 HA SERVO VALVE.......................................................................................................................................... 64 FORWARD-REVERSE SHUTTLE VALVE........................................................................................................................... 65 TRANSFER................................................................................................................................................ 66 CLUTCH SOLENOID VALVE................................................................................................................................... 77 AXLE.................................................................................................................................................... 78 DIFFERENTIAL............................................................................................................................................ 80 LIMITED-SLIP DIFFERENTIAL............................................................................................................................... 86 FINAL DRIVE............................................................................................................................................. 90 AXLE MOUNTING AND CENTER HINGE PIN...................................................................................................................... 92 STEERING PIPING......................................................................................................................................... 97 STEERING COLUMN......................................................................................................................................... 98 PRIORITY VALVE.......................................................................................................................................... 99 ORBIT-ROLL VALVE........................................................................................................................................102 2-WAY RESTRICTOR VALVE..................................................................................................................................110 CUSHION VALVE...........................................................................................................................................111 STEERING CYLINDER.......................................................................................................................................112 EMERGENCY STEERING PIPING...............................................................................................................................114 EMERGENCY STEERING VALVE................................................................................................................................115 BRAKE PIPING............................................................................................................................................118 BRAKE VALVE.............................................................................................................................................119 INCHING VALVE...........................................................................................................................................123 CHARGE VALVE............................................................................................................................................124 ACCUMULATOR (FOR BRAKE).................................................................................................................................128 SLACK ADJUSTER..........................................................................................................................................129 BRAKE...................................................................................................................................................132 PARKING BRAKE CONTROL...................................................................................................................................135 PARKING BRAKE...........................................................................................................................................136 HYDRAULIC PIPING........................................................................................................................................138 WORK EQUIPMENT LEVEL LINKAGE............................................................................................................................142 HYDRAULIC TANK..........................................................................................................................................147 4-GEAR PUMP UNIT........................................................................................................................................150 ACCUMULATOR (FOR PPC CIRCUIT)...........................................................................................................................152 LOCK VALVE..............................................................................................................................................153 BYPASS VALVE............................................................................................................................................154 QUICK COUPLER VALVE.....................................................................................................................................157 E.C.S.S. VALVE..........................................................................................................................................158 ACCUMULATOR(FOR E.C.S.S.)...............................................................................................................................160 HYDRAULIC PIPING OF COOLING SYSTEM......................................................................................................................161 COOLING FAN MOTOR.......................................................................................................................................162 WORK EQUIPMENT CONTROL VALVE............................................................................................................................164 WORK EQUIPMENT PPC VALVE................................................................................................................................177 ATTACHMENT PPC VALVE....................................................................................................................................186 WORK EQUIPMENT LINKAGE..................................................................................................................................190 BUCKET..................................................................................................................................................194 CONTROL OF BUCKET POSITIONER,BOOM KICK-OUT,AND DUMP SPEED...............................................................................................197 WORK EQUIPMENT CYLINDER.................................................................................................................................211 AIR CONDITIONER.........................................................................................................................................214 MACHINE MONITORING SYSTEM...............................................................................................................................216 MACHINE MONITOR.........................................................................................................................................225 LIST OF ITEMS DISPLAYED ON MONITOR......................................................................................................................226 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...............................................................................................................252 HST CONTROLLER..........................................................................................................................................256 KOMTRAX SYSTEM..........................................................................................................................................257 ENGINE START CIRCUIT....................................................................................................................................259 ENGINE STOP CIRCUIT.....................................................................................................................................261 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)........................................................................................................262 PARKING BRAKE CIRCUIT...................................................................................................................................263 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.............................................................................................................266 SENSORS.................................................................................................................................................267 20 TESTING AND ADJUSTING....................................................................................................................................273 STANDARD VALUE TABLE FOR ENGINE.........................................................................................................................274 STANDARD VALUE TABLE FOR CHASSIS........................................................................................................................275 TESTING AND ADJUSTING...................................................................................................................................279 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.....................................................................................................280 MEASURING ENGINE SPEED..............................................................................................................................282 MEASURING EXHAUST GAS COLOR.........................................................................................................................284 ADJUSTING VALVE CLEARANCE...........................................................................................................................285 MEASURING COMPRESSION PRESSURE......................................................................................................................287 MEASURING BLOW-BY PRESSURE..........................................................................................................................288 TESTING AND ADJUSTING FUEL INJECTION TIMIING........................................................................................................289 MEASURING ENGINE OIL PRESSURE.......................................................................................................................290 MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL..............................................................................................291 ADJUSTING ENGINE STOP SOLENOID......................................................................................................................293 ADJUSTING ENGINE SPEED SENSOR.......................................................................................................................294 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.......................................................................................294 MEASURING DIRECTIONAL LEVER.........................................................................................................................295 TESTING AND ADJUSTING HST OIL PRESSURE..............................................................................................................296 MEASURING CLUTCH CONTROL PRESSURE...................................................................................................................301 TESTING AND ADJUSTING STEERING WHEEL................................................................................................................302 TESTING AND ADJUSTING STEERING OIL PRESSURE.........................................................................................................304 BLEEDING AIR FROM STEERING CIRCUIT..................................................................................................................306 TESTING HYDRAULIC FAN...............................................................................................................................307 MEASURING BRAKE PEDAL...............................................................................................................................308 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...........................................................................................................309 MEASURING BRAKE PERFORMANCE.........................................................................................................................310 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...................................................................................................311 MEASURING BRAKE OIL PRESSURE........................................................................................................................312 MEASURING WEAR OF BRAKE DISC........................................................................................................................314 BLEEDING AIR FORM BRAKE CIRCUIT.....................................................................................................................315 MEASURING PARKING BRAKE PERFORMANCE.................................................................................................................316 TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE...................................................................................................317 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER................................................................................................318 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................319 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...............................................................................................320 BLEEDING AIR........................................................................................................................................322 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...................................................................................................323 TESTING AND ADJUSTING BUCKET POSITIONER.............................................................................................................324 TESTING AND ADJUSTING OF BOOM KICK-OUT..............................................................................................................325 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP....................................................................................................326 PROCEDURE FOR CHECKING DIODE........................................................................................................................327 METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...................................................................................................328 STARTING KOMTRAX TERMINAL OPERATIONS................................................................................................................329 INDICATOR LAMPS OF KOMTRAX TERMINAL.................................................................................................................333 SPECIAL FUNCTIONS OF MACHINE MONITOR................................................................................................................337 FLOW OF MODES AND FUNCTIONS.........................................................................................................................338 PM CLINIC INSPECTION CHART..........................................................................................................................356 TROUBLESHOOTING.........................................................................................................................................359 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................360 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................................................361 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...........................................................................................................362 CHECK BEFORE TROUBLESHOOTING........................................................................................................................370 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................371 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO..........................................................................................372 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................................376 T-ADAPTER TABLE.....................................................................................................................................398 CONNECTION TYPES AND MOUNTING LOCATIONS.............................................................................................................401 CONNECTION LAYOUT DRAWING...........................................................................................................................408 TROUBLESHOOTING OF HST CONTROLLER SYSTEM(HST MODE)..................................................................................................413 HST CONTROLLER SYSTEM DIAGRAM...................................................................................................................414 BEFORE TROUBLESHOOTING CODE DISPLAY.............................................................................................................416 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM........................................................................................................417 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..................................................................................................418 ERROR CODE [989F00](HST MOTOR PROTECTION CAUTION(00))...........................................................................................420 ERROR CODE [DHH1KX](HST OIL PRESSURE SENSOR INPUT SIGNAL OUTISIDE RANGE(KX))....................................................................421 ERROR CODE [DLE2LC](ENGINE REVOLATION SENSOR REVOLUTION SPEED SIGNAL MISMATCH(LC))..............................................................423 ERROR CODE [DW26KZ](MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).............................................................424 ERROR CODE [DX19KZ](MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).............................................................426 ERROR CODE [DX20KZ](CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))..............................................................428 [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))..............................................................430 [HST-2] (TRAVEL SPEED DOES NOT SHIFTED).........................................................................................................432 [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED..............................................................................435 [HST-4] (TRAVEL SPED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)..............................................437 [HST-5] (TRAVEL SPEED IS NOT INCREASED).........................................................................................................439 TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE).........................................................................................................449 MONITOR SYSTEM CIRCUIT DIAGRAM..................................................................................................................450 BEFORE TROUBLESHOOTING CODE DISPLAY.............................................................................................................454 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM........................................................................................................455 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..................................................................................................456 FAILURE CODE [15BONX](HST OIL FILTER CLOGGED(NX))...............................................................................................458 FAILURE CODE [2G42ZG](DECREASED BRAKE OIL PRESSURE(ZG)).........................................................................................459 FAILURE CODE [989FOO](HST MOTOR PROTECTION CAUTION(00)).........................................................................................460 FAILURE CODE [989FN1](HST OVERRUNNING (N1)).....................................................................................................461 FAILURE CODE [AB00L6](DEFECTIVE BATTERY CHARGING CIRCUIT (L6))..................................................................................462 FAILURE CODE [AB00MA](DEFECTIVE BATTERY CHARGING CIRCUIT (MA))..................................................................................463 FAILURE CODE [B@BAZG](DEGREASED ENGINE OIL PRESSURE(ZG))........................................................................................464 FAILURE CODE [B@BCNS](ENGINE WATER TEMPERATURE OVERHEATING (NS))................................................................................465 FAILURE CODE [B@BCZK](ALARM INDICATING LOW COOLANT LEVEL (ZK))..................................................................................466 FAILURE CODE [B@C7NS](AXLE OIL TEMPERATURE OVERHEATING (NS))....................................................................................467 FAILURE CODE [B@CRNS](HST OIL TEMPERATURE OVERHEATING (NS)).....................................................................................468 FAILURE CODE [D5ZHL6](STARTING SWITCH"C"(IGN"C") INPUT FAILURE (L6))............................................................................470 FAILURE CODE [DAFOKT](CONTROLLER INSIDE FAILURE (KT))...........................................................................................472 FAILURE CODE [DAJ0KR](HST CONTROLLER COMMUNICATION FAILURE (KR))................................................................................474 FAILURE CODE [DD15LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1) INPUT ERROR(LD)).................................................476 FAILURE CODE [DD16LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2) INPUT ERROR(LD)).................................................477 FAILURE CODE [DD17LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3 )INPUT ERROR(LD)).................................................478 FAILURE CODE [DD18LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4)INPUT ERROR (LD)).................................................479 FAILURE CODE [DDK3KB](MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB))..........................................................................480 FAILURE CODE [DDS5L6](DECREASED STEERING OIL PRESSURE(L6))......................................................................................482 FAILURE CODE [DGE2KX](ENGINE WATER TEMPERATURE (HIGH TEMPERATURE)SENSOR SYSTEM FAILURE(KX)).....................................................483 FAILURE CODE [DGE3L6](ENGINE WATER TEMPERATURE(LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6)).......................................................484 FAILURE CODE [DGH1KX](HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))............................................................................485 FAILURE CODE [DGR4KA](AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA)).....................................................................486 FAILURE CODE [DGR4KX](AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))...........................................................................487 FAILURE CODE [DHE4L6](ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))......................................................................488 [MON-1](THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON).....................................................................................490 [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).................................................................................494 [MON-3] (THE ENGINE TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)....495 [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)........496 [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.).......................................................................................497 [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON).............................................................................498 [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)..............................................................................499 [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)..................................................................500 [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH1))..............................................................501 [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2))............................................................502 [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3))............................................................503 [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4))............................................................504 [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)..............................................................................................505 [MON-14] THE WIPER DOES NOT FUNCTION............................................................................................................506 [MON-15] THE LAMPS DO NOT WORK PROPERLY.........................................................................................................506 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).......................................................................................................507 ELECTRICAL SYSTEM DIAGRAM.......................................................................................................................508 PARKING BRAKE RELATED DIAGRAM...................................................................................................................512 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM .......................................................................................................514 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..................................................................................................516 [E-1] (THE ENGINE DOES NOT START)...............................................................................................................518 [E-2] (THE ENGINE DOES NOT STOP)................................................................................................................524 [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)....................................................................................................526 [E-4] (THE PARKING BRAKE (MECHANICAL TYPE)DOES NOT FUNCTION)....................................................................................530 [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION).......................................................................................537 [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...................................................................................540 [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...........................................................................543 [E-8] (THE WIPER DOES NOT FUNCTION).............................................................................................................544 [E-9] (THE WINDOW WASHER DOES NOT FUNCTION).....................................................................................................550 [E-10] (LAMPS DO NOT WORK PROPERLY).............................................................................................................556 [E-11] (THE HORN DOES NOT SOUND)................................................................................................................559 [E-12] (DEFECTIVE THE AIR CONDITIONER)..........................................................................................................570 [E-13] (DEFECTIVE AIR CONDITIONER)..............................................................................................................572 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE).............................................................................................581 METHOD OF USING TROUBLESHOOTING CHART...........................................................................................................582 FAILURE CODE AND CAUSE TABLE....................................................................................................................584 H-1 THE MACHINE DOES NOT START..................................................................................................................586 H-2 THE TRAVEL SPEED IS SLOW....................................................................................................................587 H-3 THE THRUSTING FORCE IS WEAK.................................................................................................................588 H-4 ENGINE STALLS WHEN TRAVELLING OR ENGINE SPEED DROPS EXCESSIVELY.............................................................................589 H-5 THE GEAR IS NOT SHIFTED.....................................................................................................................590 H-6 THE STEERING WHEEL DOES NOT TURN............................................................................................................591 H-7 THE STEERING WHEEL IS HEAVY.................................................................................................................592 H-8 STEERING WHEEL SHAKES OR JERKS .............................................................................................................593 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING.......................................................................................593 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL..............................................................................................594 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED....................................................................................................595 H-12 THE LIFT ARM DOES NOT RISE OR LOWER........................................................................................................597 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.....................................................................598 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ..........................................................................599 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)............................................................599 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...............................................................................................599 H-17 THE LIFT ARM WOBBLES DURING OPERATION......................................................................................................599 H-18 WHEN THE CONTROL LEVER IS SWITCHED FORM "HOLD" TO "RAISE" ,THE LIFT ARM FALLS TEMPORARILY..................................................600 H-19 THE BUCKET DOES NOT TILT BACK..............................................................................................................601 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT .........................................................................602 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILITNG-BACK.............................................................................603 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET............................................................................................603 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.................................................................................................603 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVES IS SET TO "HOLD")...................................................604 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY.....................................................604 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...............................................................604 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.........................................................................605 TROUBLESHOOTING OF ENGINE (S MODE)..................................................................................................................607 METHOD OF USING TROUBLESHOOTING CHARTS..........................................................................................................608 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)....................................................................................612 S-2 ENGINE DOES NOT START.......................................................................................................................614 (1) ENGINE DOES NOT TURN....................................................................................................................614 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................................................................615 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS NOT BEING INJECTED)...........................................................616 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).........................................................................................617 S-4 ENGINE STOPS DURING OPERATIONS..............................................................................................................618 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)....................................................................................................619 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)........................................................................................................620 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...............................................................................................621 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).....................................................................................622 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................623 S-10 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................................624 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN......................................................................625 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROPS IN OIL PRESSURE)................................................................................626 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)........................................................................................................627 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...........................................................................................628 S-15 ABNORMAL NOISE IS MADE.....................................................................................................................629 S-16 VIBRATION IS EXCESSIVE.....................................................................................................................630 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................631 HOW TO READ THIS MANUAL.................................................................................................................................632 PRECAUTIONS WHEN PREFORMING OPERATION...................................................................................................................634 SPECIAL TOOL LIST.......................................................................................................................................636 SKETCHES OF SPECIAL TOOLS...............................................................................................................................639 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................................................................................................646 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY......................................................................................................651 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................652 REMOVAL AND INSTALLATION OF ENGINE......................................................................................................................660 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................667 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER ASSEMBLY....................................................................................................668 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................670 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..........................................................................................672 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................673 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY...........................................................................................................675 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................678 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY......................................................................................................699 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY......................................................................................................701 REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY.........................................................................................................708 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY..........................................................................................................709 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY.......................................................................................................712 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................720 REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...........................................................................................747 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY........................................................................................................750 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY........................................................................................................751 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.......................................................................................753 REMOVAL AND INSTALLATION OF TRAVEL DAMPER VAVLE ASSEMBLY................................................................................................754 REMOVAL AND INSTALLATION OF HYDRAULIC TANK..............................................................................................................756 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....................................................................................................757 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................764 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................772 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...........................................................................................777 REMOVAL AND INSTALLATION OF CENTER HINGE PIN............................................................................................................785 REMOVAL AND INSTALLATION OF COUNTERWEIGHT...............................................................................................................792 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...............................................................................................794 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................................................797 REMOVAL AND INSTALLATION OF MONITOR PANEL...............................................................................................................798 90 OTHERS...................................................................................................................................................801 HYDRAULIC CIRCUIT DIAGRAM WA200-5....................................................................................................................... 0 HYDRAULIC CIRCUIT DIAGRAM WA200PT-5..................................................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CAB).................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CAB).................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CAB).................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CAB).................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CAB)......................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CAB)......................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CAB)......................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CANOPY)................................................................................. 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CANOPY)................................................................................. 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CANOPY)................................................................................. 0 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CANOPY)................................................................................. 0 ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CANOPY)...................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CANOPY)...................................................................................... 0 ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CANOPY)...................................................................................... 0
DESCRIPTION:
KOMATSU WA200-5 WA200PT-5 SHOP MANUAL SEBM0333-10 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 26/12/24
