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Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual SEBM033307 – PDF DOWNLOAD
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Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual
MACHINE MODEL SERIAL NUMBER
WA200-5 65001 and up
WA200PT-5 65001 and up
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Description
Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA200-5, WA200PT-5
Serial Number: 65001 and up
Book Code: SEBM033307
Language: English
Pages: 777
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual
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.
TABLE OF CONTENTS:
Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual
COVER ...................................................................................................................................................... 1 CONTENTS.................................................................................................................................................... 2 01 GENERAL.................................................................................................................................................. 29 GENERAL ASSEMBLY DRAWINGS............................................................................................................................... 30 SPECIFICATIONS.......................................................................................................................................... 31 WEIGHT TABLE............................................................................................................................................ 35 LIST OF LUBRICANT AND COOLANT........................................................................................................................... 37 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD.............................................................................................................. 38 ENGINE MOUNT AND TRANSFER MOUNT......................................................................................................................... 39 DAMPER ................................................................................................................................................. 40 COOLING SYSTEM ......................................................................................................................................... 41 TRANSFER OIL COOLER..................................................................................................................................... 42 POWER TRAIN............................................................................................................................................. 45 POWER TRAIN SYSTEM DIAGRAM.............................................................................................................................. 46 DRIVE SHAFT(PROPELLER SHAFT)............................................................................................................................ 48 HST HYDRAULIC PIPING DIAGRAM............................................................................................................................ 49 HST PUMP................................................................................................................................................ 50 HIGH-PRESSURE RELIEF VALVE.............................................................................................................................. 52 LOW-PRESSURE RELIEF VALVE............................................................................................................................... 54 HST CHARGE PUMP......................................................................................................................................... 55 SPEED-RELATED VALVE(DA VALVE)........................................................................................................................... 56 HIGH-PRESSURE CUT-OFF VALVE............................................................................................................................. 57 HST MOTOR............................................................................................................................................... 58 EP SERVO VALVE.......................................................................................................................................... 61 HA SERVO VALVE.......................................................................................................................................... 62 FORWARD-REVERSE SHUTTLE VALVE........................................................................................................................... 63 TRANSFER................................................................................................................................................ 64 CLUTCH SOLENOID VALVE................................................................................................................................... 75 AXLE.................................................................................................................................................... 76 DIFFERENTIAL............................................................................................................................................ 78 LIMITED-SLIP DIFFERENTIAL............................................................................................................................... 84 FINAL DRIVE............................................................................................................................................. 88 AXLE MOUNTING AND CENTER HINGE PIN...................................................................................................................... 90 STEERING PIPING......................................................................................................................................... 95 STEERING COLUMN......................................................................................................................................... 96 PRIORITY VALVE.......................................................................................................................................... 97 ORBIT-ROLL VALVE........................................................................................................................................100 2-WAY RESTRICTOR VALVE..................................................................................................................................108 CUSHION VALVE...........................................................................................................................................109 STEERING CYLINDER.......................................................................................................................................110 EMERGENCY STEERING PIPING...............................................................................................................................112 EMERGENCY STEERING VALVE................................................................................................................................113 BRAKE PIPING............................................................................................................................................116 BRAKE VALVE.............................................................................................................................................117 INCHING VALVE...........................................................................................................................................121 CHARGE VALVE............................................................................................................................................122 ACCUMULATOR (FOR BRAKE).................................................................................................................................126 SLACK ADJUSTER..........................................................................................................................................127 BRAKE...................................................................................................................................................129 PARKING BRAKE CONTROL...................................................................................................................................132 PARKING BRAKE...........................................................................................................................................133 HYDRAULIC PIPING........................................................................................................................................134 WORK EQUIPMENT LEVEL LINKAGE............................................................................................................................138 HYDRAULIC TANK..........................................................................................................................................142 4-GEAR PUMP UNIT........................................................................................................................................144 ACCUMULATOR (FOR PPC CIRCUIT)...........................................................................................................................146 LOCK VALVE..............................................................................................................................................147 BYPASS VALVE............................................................................................................................................148 QUICK COUPLER VALVE.....................................................................................................................................151 E.C.S.S. VALVE..........................................................................................................................................152 ACCUMULATOR(FOR E.C.S.S.)...............................................................................................................................154 HYDRAULIC PIPING OF COOLING SYSTEM......................................................................................................................155 COOLING FAN MOTOR.......................................................................................................................................156 WORK EQUIPMENT CONTROL VALVE............................................................................................................................158 WORK EQUIPMENT PPC VALVE................................................................................................................................171 ATTACHMENT PPC VALVE....................................................................................................................................179 WORK EQUIPMENT LINKAGE..................................................................................................................................183 BUCKET..................................................................................................................................................187 CONTROL OF BUCKET POSITIONER,BOOM KICK-OUT,AND DUMP SPEED...............................................................................................189 WORK EQUIPMENT CYLINDER.................................................................................................................................203 AIR CONDITIONER.........................................................................................................................................206 MACHINE MONITORING SYSTEM...............................................................................................................................207 MACHINE MONITOR.........................................................................................................................................216 LIST OF ITEMS DISPLAYED ON MONITOR......................................................................................................................217 ELECTRICAL SYSTEM(HST CONTROLLER SYSTEM)................................................................................................................243 HST CONTROLLER..........................................................................................................................................247 ENGINE START CIRCUIT....................................................................................................................................248 ENGINE STOP CIRCUIT.....................................................................................................................................250 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)........................................................................................................251 PARKING BRAKE CIRCUIT...................................................................................................................................252 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.............................................................................................................255 SENSORS.................................................................................................................................................256 20 TESTING AND ADJUSTING....................................................................................................................................262 STANDARD VALUE TABLE FOR ENGINE.........................................................................................................................263 STANDARD VALUE TABLE FOR CHASSIS........................................................................................................................264 TESTING AND ADJUSTING...................................................................................................................................268 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING.....................................................................................................269 MEASURING ENGINE SPEED..............................................................................................................................271 MEASURING EXHAUST GAS COLOR.........................................................................................................................273 ADJUSTING VALVE CLEARANCE...........................................................................................................................274 MEASURING COMPRESSION PRESSURE......................................................................................................................276 MEASURING BLOW-BY PRESSURE..........................................................................................................................277 TESTING AND ADJUSTING FUEL INJECTION TIMIING........................................................................................................278 MEASURING ENGINE OIL PRESSURE.......................................................................................................................279 MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL..............................................................................................280 ADJUSTING ENGINE STOP SOLENOID......................................................................................................................282 ADJUSTING ENGINE SPEED SENSOR.......................................................................................................................283 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.......................................................................................283 MEASURING DIRECTIONAL LEVER.........................................................................................................................284 TESTING AND ADJUSTING HST OIL PRESSURE..............................................................................................................285 MEASURING CLUTCH CONTROL PRESSURE...................................................................................................................290 TESTING AND ADJUSTING STEERING WHEEL................................................................................................................291 TESTING AND ADJUSTING STEERING OIL PRESSURE.........................................................................................................293 BLEEDING AIR FROM STEERING CIRCUIT..................................................................................................................295 TESTING HYDRAULIC FAN...............................................................................................................................296 MEASURING BRAKE PEDAL...............................................................................................................................297 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...........................................................................................................298 MEASURING BRAKE PERFORMANCE.........................................................................................................................299 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...................................................................................................300 MEASURING BRAKE OIL PRESSURE........................................................................................................................301 MEASURING WEAR OF BRAKE DISC........................................................................................................................303 BLEEDING AIR FORM BRAKE CIRCUIT.....................................................................................................................304 MEASURING PARKING BRAKE PERFORMANCE.................................................................................................................305 TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE...................................................................................................306 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER................................................................................................307 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................308 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...............................................................................................309 BLEEDING AIR........................................................................................................................................311 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...................................................................................................312 TESTING AND ADJUSTING BUCKET POSITIONER.............................................................................................................313 TESTING AND ADJUSTING OF BOOM KICK-OUT..............................................................................................................314 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP....................................................................................................315 PROCEDURE FOR CHECKING DIODE........................................................................................................................316 METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...................................................................................................317 SPECIAL FUNCTIONS OF MACHINE MONITOR................................................................................................................318 FLOW OF MODES AND FUNCTIONS.........................................................................................................................319 PM CLINIC INSPECTION CHART..........................................................................................................................337 TROUBLESHOOTING.........................................................................................................................................339 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................340 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................................................341 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...........................................................................................................342 CHECK BEFORE TROUBLESHOOTING........................................................................................................................350 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................351 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO..........................................................................................352 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................................355 T-ADAPTER TABLE.....................................................................................................................................377 CONNECTION TYPES AND MOUNTING LOCATIONS.............................................................................................................380 CONNECTION LAYOUT DRAWING...........................................................................................................................386 TROUBLESHOOTING OF HST CONTROLLER SYSTEM(HST MODE)..................................................................................................391 HST CONTROLLER SYSTEM DIAGRAM...................................................................................................................392 BEFORE TROUBLESHOOTING CODE DISPLAY.............................................................................................................394 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM........................................................................................................395 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..................................................................................................396 ERROR CODE [989F00](HST MOTOR PROTECTION CAUTION(00))...........................................................................................398 ERROR CODE [DHH1KX](HST OIL PRESSURE SENSOR INPUT SIGNAL OUTISIDE RANGE(KX))....................................................................399 ERROR CODE [DLE2LC](ENGINE REVOLATION SENSOR REVOLUTION SPEED SIGNAL MISMATCH(LC))..............................................................401 ERROR CODE [DW26KZ](MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).............................................................402 ERROR CODE [DX19KZ](MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).............................................................404 ERROR CODE [DX20KZ](CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))..............................................................406 [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))..............................................................408 [HST-2] (TRAVEL SPEED DOES NOT SHIFTED).........................................................................................................410 [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED..............................................................................413 [HST-4] (TRAVEL SPED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)..............................................415 [HST-5] (TRAVEL SPEED IS NOT INCREASED).........................................................................................................417 TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE).........................................................................................................426 MONITOR SYSTEM CIRCUIT DIAGRAM..................................................................................................................427 BEFORE TROUBLESHOOTING CODE DISPLAY.............................................................................................................431 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM........................................................................................................432 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..................................................................................................433 FAILURE CODE [15BONX](HST OIL FILTER CLOGGED(NX))...............................................................................................435 FAILURE CODE [2G42ZG](DECREASED BRAKE OIL PRESSURE(ZG)).........................................................................................436 FAILURE CODE [989FOO](HST MOTOR PROTECTION CAUTION(00)).........................................................................................437 FAILURE CODE [989FN1](HST OVERRUNNING (N1)).....................................................................................................438 FAILURE CODE [AB00L6](DEFECTIVE BATTERY CHARGING CIRCUIT (L6))..................................................................................439 FAILURE CODE [AB00MA](DEFECTIVE BATTERY CHARGING CIRCUIT (MA))..................................................................................440 FAILURE CODE [B@BAZG](DEGREASED ENGINE OIL PRESSURE(ZG))........................................................................................441 FAILURE CODE [B@BCNS](ENGINE WATER TEMPERATURE OVERHEATING (NS))................................................................................442 FAILURE CODE [B@BCZK](ALARM INDICATING LOW COOLANT LEVEL (ZK))..................................................................................443 FAILURE CODE [B@C7NS](AXLE OIL TEMPERATURE OVERHEATING (NS))....................................................................................444 FAILURE CODE [B@CRNS](HST OIL TEMPERATURE OVERHEATING (NS)).....................................................................................445 FAILURE CODE [D5ZHL6](STARTING SWITCH"C"(IGN"C") INPUT FAILURE (L6))............................................................................446 FAILURE CODE [DAFOKT](CONTROLLER INSIDE FAILURE (KT))...........................................................................................448 FAILURE CODE [DAJ0KR](HST CONTROLLER COMMUNICATION FAILURE (KR))................................................................................449 FAILURE CODE [DD15LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1) INPUT ERROR(LD)).................................................451 FAILURE CODE [DD16LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2) INPUT ERROR(LD)).................................................452 FAILURE CODE [DD17LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3 )INPUT ERROR(LD)).................................................453 FAILURE CODE [DD18LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4)INPUT ERROR (LD)).................................................454 FAILURE CODE [DDK3KB](MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB))..........................................................................455 FAILURE CODE [DDS5L6](DECREASED STEERING OIL PRESSURE(L6))......................................................................................457 FAILURE CODE [DGE2KX](ENGINE WATER TEMPERATURE (HIGH TEMPERATURE)SENSOR SYSTEM FAILURE(KX)).....................................................458 FAILURE CODE [DGE3L6](ENGINE WATER TEMPERATURE(LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6)).......................................................459 FAILURE CODE [DGH1KX](HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))............................................................................460 FAILURE CODE [DGR4KA](AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA)).....................................................................461 FAILURE CODE [DGR4KX](AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))...........................................................................462 FAILURE CODE [DHE4L6](ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))......................................................................463 [MON-1](THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON).....................................................................................464 [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).................................................................................468 [MON-3] (THE ENGINE TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)....469 [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.)........470 [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.).......................................................................................471 [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON).............................................................................472 [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)..............................................................................473 [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)..................................................................474 [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH1))..............................................................475 [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2))............................................................476 [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3))............................................................477 [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4))............................................................478 [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)..............................................................................................479 [MON-14] THE WIPER DOES NOT FUNCTION............................................................................................................480 [MON-15] THE LAMPS DO NOT WORK PROPERLY.........................................................................................................480 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).......................................................................................................481 ELECTRICAL SYSTEM DIAGRAM.......................................................................................................................482 PARKING BRAKE RELATED DIAGRAM...................................................................................................................485 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM .......................................................................................................487 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..................................................................................................488 [E-1] (THE ENGINE DOES NOT START)...............................................................................................................490 [E-2] (THE ENGINE DOES NOT STOP)................................................................................................................496 [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)....................................................................................................498 [E-4] (THE PARKING BRAKE (MECHANICAL TYPE)DOES NOT FUNCTION)....................................................................................502 [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION).......................................................................................507 [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...................................................................................510 [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...........................................................................513 [E-8] (THE WIPER DOES NOT FUNCTION).............................................................................................................514 [E-9] (THE WINDOW WASHER DOES NOT FUNCTION).....................................................................................................519 [E-10] (LAMPS DO NOT WORK PROPERLY).............................................................................................................524 [E-11] (THE HORN DOES NOT SOUND)................................................................................................................527 [E-12] (DEFECTIVE THE AIR CONDITIONER)..........................................................................................................538 [E-13] (DEFECTIVE AIR CONDITIONER)..............................................................................................................540 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE).............................................................................................548 METHOD OF USING TROUBLESHOOTING CHART...........................................................................................................549 FAILURE CODE AND CAUSE TABLE....................................................................................................................551 H-1 THE MACHINE DOES NOT START..................................................................................................................553 H-2 THE TRAVEL SPEED IS SLOW....................................................................................................................554 H-3 THE THRUSTING FORCE IS WEAK.................................................................................................................555 H-4 ENGINE STALLS WHEN TRAVELLING OR ENGINE SPEED DROPS EXCESSIVELY.............................................................................556 H-5 THE GEAR IS NOT SHIFTED.....................................................................................................................557 H-6 THE STEERING WHEEL DOES NOT TURN............................................................................................................558 H-7 THE STEERING WHEEL IS HEAVY.................................................................................................................559 H-8 STEERING WHEEL SHAKES OR JERKS .............................................................................................................560 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING.......................................................................................560 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL..............................................................................................561 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED....................................................................................................562 H-12 THE LIFT ARM DOES NOT RISE OR LOWER........................................................................................................563 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.....................................................................564 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ..........................................................................565 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)............................................................565 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...............................................................................................565 H-17 THE LIFT ARM WOBBLES DURING OPERATION......................................................................................................565 H-18 WHEN THE CONTROL LEVER IS SWITCHED FORM "HOLD" TO "RAISE" ,THE LIFT ARM FALLS TEMPORARILY..................................................566 H-19 THE BUCKET DOES NOT TILT BACK..............................................................................................................567 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT .........................................................................568 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILITNG-BACK.............................................................................569 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET............................................................................................569 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.................................................................................................569 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVES IS SET TO "HOLD")...................................................570 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY.....................................................570 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...............................................................570 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.........................................................................571 TROUBLESHOOTING OF ENGINE (S MODE)..................................................................................................................572 METHOD OF USING TROUBLESHOOTING CHARTS..........................................................................................................573 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)....................................................................................577 S-2 ENGINE DOES NOT START.......................................................................................................................579 (1) ENGINE DOES NOT TURN....................................................................................................................579 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................................................................580 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS NOT BEING INJECTED)...........................................................581 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).........................................................................................582 S-4 ENGINE STOPS DURING OPERATIONS..............................................................................................................583 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)....................................................................................................584 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)........................................................................................................585 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...............................................................................................586 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).....................................................................................587 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................................588 S-10 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................................589 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN......................................................................590 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROPS IN OIL PRESSURE)................................................................................591 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)........................................................................................................592 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...........................................................................................593 S-15 ABNORMAL NOISE IS MADE.....................................................................................................................594 S-16 VIBRATION IS EXCESSIVE.....................................................................................................................595 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................596 HOW TO READ THIS MANUAL.................................................................................................................................597 PRECAUTIONS WHEN PREFORMING OPERATION...................................................................................................................599 SPECIAL TOOL LIST.......................................................................................................................................601 SKETCHES OF SPECIAL TOOLS...............................................................................................................................604 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................................................................................................611 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY......................................................................................................616 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................617 REMOVAL AND INSTALLATION OF ENGINE......................................................................................................................625 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................632 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER ASSEMBLY....................................................................................................633 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................635 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..........................................................................................637 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................638 REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY...........................................................................................................640 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................643 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY......................................................................................................662 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY......................................................................................................664 REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY.........................................................................................................669 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY..........................................................................................................670 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY.......................................................................................................673 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................681 REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...........................................................................................707 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY........................................................................................................710 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY........................................................................................................711 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.......................................................................................713 REMOVAL AND INSTALLATION OF TRAVEL DAMPER VAVLE ASSEMBLY................................................................................................714 REMOVAL AND INSTALLATION OF HYDRAULIC TANK..............................................................................................................716 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....................................................................................................717 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................724 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................732 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...........................................................................................737 REMOVAL AND INSTALLATION OF CENTER HINGE PIN............................................................................................................745 REMOVAL AND INSTALLATION OF COUNTERWEIGHT...............................................................................................................752 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...............................................................................................754 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................................................757 REMOVAL AND INSTALLATION OF MONITOR PANEL...............................................................................................................758 90 OTHERS...................................................................................................................................................761 HYDRAULIC CIRCUIT DIAGRAM ..............................................................................................................................762 WA200-5.............................................................................................................................................762 HYDRAULIC CIRCUIT DIAGRAM ..............................................................................................................................763 WA200PT-5...........................................................................................................................................763 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................764 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................765 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................766 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CAB)....................................................................................767 ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CAB).........................................................................................768 ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CAB).........................................................................................769 ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CAB).........................................................................................770 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................771 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................772 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................773 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CANOPY).................................................................................774 ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CANOPY)......................................................................................775 ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CANOPY)......................................................................................776 ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CANOPY)......................................................................................777
KOMATSU WA200-5, WA200PT-5 WHEEL LOADER SHOP MANUAL SEBM033307 – PDF DOWNLOAD:
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- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
2 reviews for Komatsu WA200-5, WA200PT-5 Wheel Loader Shop Manual SEBM033307 – PDF DOWNLOAD
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Silas Chris –
Mylo Byron –