Komatsu WA200-5H WA200PT-5H Wheel Loader Shop Manual VEBM220100 PDF

Description

Komatsu WA200-5H WA200PT-5H Wheel Loader Shop Manual VEBM220100  – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA200-5H WA200PT-5H Wheel Loader Shop Manual VEBM220100  – PDF DOWNLOAD

Language : English
Pages : 780
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA200-5H WA200PT-5H Wheel Loader Shop Manual VEBM220100  – PDF DOWNLOAD

• MACHINE MODEL     SERIAL NUMBER
  WA200-5H                   H50051 and up
  WA200PT-5H               H60051 and up

CONTENTS 2
00 SAFETY 3
00 FOREWORD 0
SAFETY NOTICE 3
IMPORTANT SAFETY NOTICE 3
GENERAL PRECAUTIONS 3
PREPARATIONS FOR WORK 3
PRECAUTIONS DURING WORK 4
GENERAL 5
STRUCTURE AND FUNCTION 5
TESTING AND ADJUSTING 5
DISASSEMBLY AND ASSEMBLY 5
MAINTENANCE STANDARD 5
OTHERS 5
HOW TO READ THE SHOP MANUAL 6
VOLUMES 6
DISTRIBUTION AND UPDATING 6
FILING METHOD 6
REVISED EDITION MARK 6
REVISIONS 6
SYMBOLS 6
HOISTING INSTRUCTIONS 7
HOISTING 7
WIRE ROPES 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
Disconnection 8
Connection 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) 12
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS 12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS 13
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 13
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 13
TIGHTENING TORQUE FOR 102 ENGINE SERIES 14
Tightening torque table for hoses (taper seal type and face seal type) 14
ELECTRIC WIRE CODE 15
CLASSIFICATION BY THICKNESS 15
CLASSIFICATION BY COLOR AND CODE 15
CONVERSION TABLE 16
METHOD OF USING THE CONVERSION TABLE 16
EXAMPLE 16
Millimeters to inches 16
Millimeters to Inches 17
Kilogram to Pound 17
Liter to U S Gallon 18
Liter to U K Gallon 18
kgm to ft lb 19
kg/cm2 to lb/in2 20
Temperature 21
UNITS 22
Example: 22
01 GENERAL 23
GENERAL ASSEMBLY DRAWINGS 15
SPECIFICATIONS 25
WEIGHT TABLE 29
LIST OF LUBRICANT AND COOLANT 31
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 0
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 33
Engine mount and transfer mount 34
Damper 35
Outline 35
Cooling system 36
Specification 36
Transfer oil cooler 37
Specification 37
Power train 38
Power train system diagram 40
Outline 41
Drive shaft (propeller shaft) 42
Outline 42
HST hydraulic piping diagram 43
HST pump 44
Specifications 44
Operation 45
Flow of power 45
Flow of oil 45
High-pressure relief valve 46
Function 46
Operation 47
Low-pressure relief valve 48
Function 48
Operation 48
HST charge pump 49
Outline 49
Specifications 49
Function 49
Speed-related valve (DA valve) 50
Function 50
Operation 50
High-pressure cut-off valve 51
Function 51
Operation 51
HST motor 52
HST motor 1 52
Specifications 52
HST motor 2 53
Specifications 53
Principle 54
Structure 54
Operation 54
EP servo valve 55
Function 55
Operation 55
HA servo valve 56
Function 56
Operation 56
Forward-reverse shuttle valve 57
Function 57
Operation 57
Transfer 58
Outline 58
Relationship between transfer clutch and transfer clutch pressure at each gear speed 58
Input shaft portion 60
Output shaft portion 62
Operation of clutch 66
When clutch is ON (fixed) 66
When clutch is OFF (released) 66
Low-speed mode 67
Operation 67
High-speed mode 68
Operation 68
Clutch solenoid valve 69
Operation 69
Axle 70
FRONT AXLE 70
REAR AXLE 71
Differential 72
FRONT DIFFERENTIAL 72
REAR DIFFERENTIAL 74
Outline 76
When traveling in a straight line 76
When turning 76
Torque proportioning differential 77
Outline 77
Operation 77
Straight travel (When the road resistances under both tires are the same) 77
Travel on soft ground (When the road resistances under both tires are different) 77
Limited-slip differential 78
Operation of limited-slip differential 80
Brake torque generation mechanism of left and right side gears (5) 80
When traveling in a straight line 80
When turning 81
Final drive 82
Outline 83
Axle mounting and center hinge pin 84
Outline 85
Steering piping 89
Steering column 90
Priority valve 91
Outline 92
Operation 92
Orbit-roll valve 94
Outline 95
Structure 95
Operation 96
CONNECTION BETWEEN HAND PUMP AND SLEEVE 100
Role of centering spring 101
2-way restrictor valve 102
Function 102
Operation 102
Cushion valve 103
Outline 103
Function 103
Steering cylinder 104
Emergency steering piping 106
Emergency steering valve 107
Operation 108
When engine and steering pump are normal 108
When engine or steering pump is abnormal 109
Brake piping 110
Brake valve 111
Outline 112
Operation 112
When only either brake operates (When either brake fails) 112
Inching valve 115
Outline 115
Charge valve 116
Function 117
Operation 118
Accumulator (for brake) 120
Function 120
Slack adjuster 121
Function 122
Operation 122
When brake is applied 122
When brake is released 122
Brake 124
Outline 125
Outline 126
When brake is applied 126
When brake is released 126
Parking brake control 127
Outline 127
Parking brake 128
Outline 128
Hydraulic piping 130
WA200-5H 130
Outline 131
WA200PT-5H 132
Outline 133
Work equipment lever linkage 134
WA200-5H 134
Multi-function joystick type 134
WA200-5H 135
2-lever type 135
(If equipped) 135
WA200PT-5H 136
Multi-function joystick type 136
WA200PT-5H 137
2-lever type 137
(If equipped) 137
Hydraulic tank 138
Specifications 138
Breather 139
Prevention of negative pressure in tank 139
Prevention of rise of pressure in tank 139
4-gear pump unit 140
SAR(2)50 + (2)32 + SBR(1)10 + 12 140
Outline 140
Accumulator (for PPC circuit) 142
Outline 142
Specifications 142
Lock valve 143
Outline 143
Bypass valve 144
WA200PT-5H 144
Operation 145
Quick coupler valve 147
WA200PT-5H 147
Outline 147
Operation 147
When quick coupler valve lever is in position “A” 147
When quick coupler valve lever is in position “B” 147
E C S S valve 148
(If equipped) 148
(E C S S : Electronically Controlled Suspension System) 148
Accumulator (for E C S S ) 150
(If equipped) 150
Function 150
Specifications 150
Hydraulic piping of coolingsystem 151
Outline 151
Cooling fan motor 152
Specifications 152
Function 153
Principle of operation 153
Work equipment control valve 154
Function 158
Operation 158
Function 159
Operation 159
Function 160
Operation 160
Operation 161
Operation 162
Operation 163
Operation 164
Operation 165
Operation 166
Work equipment PPC valve 167
Mono-lever type 167
Operation 169
2-lever type (If equipped) 173
Attachment PPC valve 176
Operation 178
Work equipment linkage 180
WA200-5H 180
WA200PT-5H 182
Bucket 184
WA200-5H 184
WA200PT-5H 185
Control of bucket positioner, boom kick-out, and dump speed 186
WA200-5H 186
Outline 187
Bucket positioner 187
Boom kick-out 187
Operation of proximity switch 188
When bucket is tilted 188
Function of proximity switch 189
When object of sensing is over sensing face of proximity switch 189
When object of sensing is apart from over sensing face of proximity switch 189
When lift arm is raised 190
Function of proximity switch 191
When object of sensing is over sensing face of proximity switch 191
When object of sensing is apart from over sensing face of proximity switch 191
WA200PT-5H 192
Outline 193
Bucket positioner or fork positioner 193
Boom kick-out 193
The dump speed control 193
Operation of proximity switch 194
When bucket is tilted 194
Function of proximity switch 195
When object of sensing is over sensing face of proximity switch 195
When object of sensing is apart from over sensing face of proximity switch 195
When lift arm is raised 196
Function of proximity switch 197
When object of sensing is over sensing face of proximity switch 197
When object of sensing is apart from over sensing face of proximity switch 197
When bucket is dumped 198
Function of proximity switch 199
When object of sensing is over sensing face of proximity switch 199
When object of sensing is apart from over sensing face of proximity switch 199
Work equipment cylinder 200
WA200-5H 200
LIFT CYLINDER 200
BUCKET CYLINDER 200
WA200PT-5H 202
LIFT CYLINDER 202
BUCKET CYLINDER 202
Air conditioner 204
AIR CONDITIONER PIPING 204
Machine monitoring system 205
Outline 205
Individual circuit diagrams of the machine monitor 207
Starting and lighting 207
Power supply and network 209
Sensing 210
HST safety control 211
Autmatic preheating 212
Machine monitor 214
List of items displayed onmonitor 215
Service mode functions 219
Items Related to the Fault History of Electric System 223
Items Related to the Fault History of Machine System 226
Real-time monitor function 228
(Reference) Inspection with real-time monitor 231
Maintenance functions 232
How to input interval 234
Setting required when optional device is installed 236
Function of selecting optional device 236
Selection of tire deviation 237
Electrical system (HSTcontroller system) 241
System diagram 241
Control function 242
HST controller 245
Input and output signals 245
Function of selecting directional selector switch 246
Outline 246
Function 246
Operation 247
When travel direction is changed with directional lever 247
When directional selector switch is selected to be used 247
When travel direction is changed with directional selector switch 247
When directional lever has priority 247
Engine start circuit 248
Function 248
Operation 249
Engine stop circuit 250
Operation 250
Preheating circuit 251
Outline 251
Operation 251
Parking brake circuit 252
Operation 253
Electronically controlled suspension system 255
Electronically Controlled Suspension System (Abbreviation: ECSS) 255
(If equipped) 255
Function 255
System operation table 255
Sensors 256
Engine speed sensor 256
Function 256
Speed sensor 256
Function 256
ENGINE OIL PRESSURE SENSOR 257
Function 257
FUEL LEVEL SENSOR 257
Function 257
COOLANT TEMPERATURE SENSOR (FOR MONITOR) 258
HST oil temperature sensor 258
Function 258
COOLANT TEMPERATURE SENSOR (FOR PREHEATING) 258
Function 258
Axle oil temperature sensor 259
Function 259
HST oil pressure sensor 259
Function 259
Steering oil pressure sensor 260
Emergency steering oil pressure sensor 260
Function 260
HST filter clogging sensor 260
Function 260
COOLANT LEVEL SENSOR 261
Function 261
20 TESTING AND ADJUSTING 263
STANDARD VALUE TABLE FOR ENGINE 265
STANDARD VALUE TABLE FOR CHASSIS 266
Tools for testing, adjusting, and troubleshooting 272
Measuring engine speed 274
Special tools required 274
MEASURING HIGH-IDLING AND LOW-IDLING SPEEDS 274
MEASURING HST STALL SPEED 275
MEASURING HYDRAULIC SPEED 275
MEASURING FULL STALL SPEED 275
Measuring exhaust gas color 276
Special tools required 276
Adjusting valve clearance 277
Special tools required 277
Measuring compression pressure 279
Special tools required 279
Measuring blow-by pressure 280
Special tools required 280
Testing and adjusting fuel injection timing 281
Special tools required 281
Measuring engine oil pressure 282
Special tools required 282
Measuring, testing operating force of accelerator pedal 283
Special tools required 283
MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL 283
OPERATING ANGLE OF ACCELERATOR PEDAL 284
Adjusting engine stop solenoid 285
Adjusting engine speed sensor 286
Testing 286
Adjusting 286
Measuring directional lever 287
Special tools required 287
Operating effort of directional lever 287
Travel of directional lever 287
Testing and adjusting HST oil pressure 288
Special tools required 288
Adjusting 291
Measuring clutch control pressure 293
Special tools required 293
Testing and adjusting steering wheel 294
Special tools required 294
MEASURING PLAY OF STEERING WHEEL 294
Method of measurement 294
MEASURING OPERATING FORCE OF STEERING WHEEL 295
Measurement method 295
MEASURING OPERATING TIME FOR STEERING WHEEL 295
Measurement method 295
Testing and adjusting steering oil pressure 296
Special tools required 296
Method of measuring main relief pressure 296
Method of adjusting main relief pressure 297
Bleeding air from steering circuit 298
Testing hydraulic fan 299
Special tools required 299
Measuring fan speed 299
Measuring oil pressure 299
Measuring brake pedal 300
Operating effort of pedal 300
Testing and adjusting brake pedal linkage 301
Testing 301
Adjusting 301
Measuring brake performance 302
Measurement method 302
Testing and adjusting accumulator charge pressure 303
Special tools required 303
Measuring 303
Adjusting 303
Measuring brake oil pressure 304
Special tools required 304
Measuring 304
Brake test tool 305
Measuring wear of brake disc 306
Special tool required 306
Bleeding air from brake circuit 307
Special tools required 307
Measuring parking brake performance 308
Measurement method 308
Testing and adjusting parking brake control cable 309
Special tool required 309
Testing 309
Adjusting 309
Measuring and adjusting work equipment control lever 310
Special tools required 310
Measurement 310
Testing and adjusting work equipment hydraulic pressure 311
Special tools required 311
Measuring condition 311
Measuring 311
Adjusting 311
Testing and adjusting work equipment PPC oil pressure 312
Special tools required 312
Measuring condition 312
Measuring 312
Bleeding air 314
Special tools required 314
Releasing remaining pressure in hydraulic circuit 315
Testing and adjusting bucket positioner 316
Testing 316
Adjusting 316
Testing and adjusting of boom kick-out 317
Testing 317
Adjusting 317
Checking proximity switch actuation display lamp 318
Proximity switch actuation display lamp (red) 318
Procedure for checking diode 319
Method of connecting T-adapter for HST controller 320
Special functions of machine monitor 321
Flow of modes and functions 322
Operator mode 325
Service mode 1 325
Service mode 2 325
Character display 325
Operating switches 325
Operator mode operation and displays 325
Failure code table 330
Procedure for switching to Service Mode 1 and screen display 332
Real-time monitoring items 337
Table of filter and oil replacement interval set items (when sipping) 338
Service mode 2 339
20 TROUBLESHOOTING 341
POINTS TO REMEMBER WHEN TROUBLESHOOTING 342
SEQUENCE OF EVENTS IN TROUBLESHOOTING 343
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 344
CHECK BEFORE TROUBLESHOOTING 352
Categories, procedure, and method of using troubleshooting charts 353
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No 354
Connection table for connector pin numbers 358
T-ADAPTER TABLE 379
CONNECTOR TYPES AND MOUNTING LOCATIONS 383
Connector layout drawing 390
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE) 395
HST controller system diagram 396
Before troubleshooting code display 398
ERROR CODE AND POSSIBLE CAUSES TABLE 398
Before troubleshooting electrical system 399
FUSE BOX CONNECTION TABLE 399
Information contained in troubuleshooting table 400
Related circuit diagram 15
Phenomena code table 401
Related circuit diagram 404
Related circuit diagram 20
Related circuit diagram 407
Related circuit diagram 409
Related circuit diagram 411
Related circuit diagram 413
Related circuit diagram 415
Related circuit diagram 417
Related circuit diagram 420
TROUBLESHOOTING OF monitor SYSTEM (mon MODE) 423
Monitor system circuit diagram 424
Before troubleshooting code display 428
ERROR CODE AND POSSIBLE CAUSES TABLE 428
Before troubleshooting electrical system 399
FUSE BOX CONNECTION TABLE 399
Information contained in troubuleshooting table 430
Related circuit diagram 15
Phenomena code table 401
Error Code [15B0NX] 432
(HST oil filter clogged (NX)) 432
Related circuit diagram 432
Error Code [2G42ZG] 433
(Decreased brake oil pressure (ZG)) 433
Related circuit diagram 433
Error Code [989F00] 434
(HST motor protection caution (00)) 434
Error Code [989FN1] 435
(HST overrunning (N1)) 435
Error Code [AB00L6] 436
(Defective battery charging circuit (L6)) 436
Related circuit diagram 436
Error Code [AB00MA] 437
(Defective battery charging circuit (MA)) 437
Related circuit diagram 437
Error Code [B@BAZG] 438
(Degreased engine oil pressure (ZG)) 438
Related circuit diagram 438
Error Code [B@BCNS] 439
(Engine water temperature overheating (NS)) 439
Related circuit diagram 439
Error Code [B@BCZK] 440
(Alarm indicating low coolant level (ZK)) 440
Related circuit diagram 440
Error Code [B@C7NS] 441
(Axle oil temperature overheating (NS)) 441
Related circuit diagram 441
Error Code [B@CRNS] 14
(HST oil temperature overheating (NS)) 442
Related circuit diagram 442
Error Code [D5ZHL6] 444
(Starting switch “C” (IGN “C”) input failure (L6)) 444
Related circuit diagram 445
Error Code [DAF0KT] 446
(Controller inside failure (KT)) 446
Error Code [DAJ0KR] 448
(HST controller communication failure (KR)) 448
Related circuit diagram 449
Error Code [DD15LD] 450
(Monitor panel mode selector switch 1 [t] (Panel switch 1) input error (LD)) 450
Related circuit diagram 450
Error Code [DD16LD] 451
(Monitor panel mode selector switch 1 [U] (Panel switch 2) input error (LD)) 451
Related circuit diagram 451
Error Code [DD17LD] 452
(Monitor panel mode selector switch 2 [<] (Panel switch 3) input error (LD)) 452
Related circuit diagram 452
Error Code [DD18LD] 453
(Monitor panel mode selector switch 2 [>] (Panel switch 4) input error (LD)) 453
Related circuit diagram 453
Error Code [DDK3KB] 454
(Multiple directional lever FR signal input (KB)) 454
Related circuit diagram 455
Error Code [DDS5L6] 456
(Decreased steering oil pressure (L6)) 456
Related circuit diagram 456
Error Code [DGE2KX] 457
(Engine water temperature (High temperature) sensor system failure (KX)) 457
Related circuit diagram 457
Error Code [DGE3L6] 458
(Engine water temperature (Low temperature) sensor system failure (L6)) 458
Related circuit diagram 458
Error Code [DGH1KX] 459
(HST oil temperature sensor system failure (KX)) 459
Related circuit diagram 459
Error Code [DGR4KA] 460
(Axle oil temperature sensor system discontinuity (KA)) 460
Related circuit diagram 460
Error Code [DGR4KX] 461
(Axle oil temperature sensor system failure (KX)) 461
Related circuit diagram 461
Error Code [DHE4L6] 462
(Engine oil pressure sensor system discontinuity (L6)) 462
Related circuit diagram 462
Troubleshooting Code [MON-1] 464
(The parking brake indicator lamp does not light ON) 464
Related circuit diagram 466
Related circuit diagram 467
Troubleshooting Code [MON-2] 468
(The brake oil pressure caution lamp does not light ON) 468
Related circuit diagram 468
Troubleshooting Code [MON-3] 469
(The engine water temperature caution lamp does not light ON, or after the engine starts, the eng 469
Related circuit diagram 469
Troubleshooting Code [MON-4] 470
(The HST oil temperature caution lamp does not light ON, or after the engine starts, the HST oil 470
Related circuit diagram 470
Troubleshooting Code [MON-5] 471
(The fuel level gauge does not rise or decrease ) 471
Related circuit diagram 471
Troubleshooting Code [MON-6] 472
(The radiator coolant level caution lamp does not light ON) 472
Related circuit diagram 472
Troubleshooting Code [MON-7] 473
(The steering oil pressure caution lamp does not light ON) 473
Related circuit diagram 473
Troubleshooting Code [MON-8] 474
(The emergency steering oil pressure indicator lamp does not light ON) 474
Related circuit diagram 474
Troubleshooting Code [MON-9] 475
(Input failure in monitor panel mode selector switch 1 [t] (Panel switch 1)) 475
Related circuit diagram 475
Troubleshooting Code [MON-10] 476
(Input failure in monitor panel mode selector switch 1 [U] (Panel switch 2)) 476
Related circuit diagram 476
Troubleshooting Code [MON-11] 477
(Input failure in monitor panel mode selector switch 2 [<] (Panel switch 3)) 477
Related circuit diagram 477
Troubleshooting Code [MON-12] 478
(Input failure in monitor panel mode selector switch 2 [>] (Panel switch 4)) 478
Related circuit diagram 478
Troubleshooting Code [MON-13] 479
(The alarm buzzer does not sound or stop) 479
Related circuit diagram 479
Troubleshooting Code [MON-14] 480
The wiper does not function 480
Troubleshooting Code [MON-15] 480
The lamps do not work properly 480
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 481
Electrical system diagram 396
Parking brake related diagram 486
Before troubleshooting electrical system 399
Information contained in troubuleshooting table 430
Troubleshooting Code [E-1] 492
(The engine does not start) 492
Troubleshooting Code [E-2] 498
(The engine does not stop) 498
Troubleshooting Code [E-3] 500
(Preheating is impossible or constant) 500
Troubleshooting Code [E-4] 504
(The parking brake (Mechanical type) does not function) 504
Troubleshooting Code [E-5] 511
(Defective boom kick-out function and cancellation) 511
Troubleshooting Code [E-6] 514
(Defective bucket positioner function and cancellation) 514
Troubleshooting Code [E-7] 517
(Defective lift arm FLOATING holding function and cancellation) 517
Troubleshooting Code [E-8] 518
(The wiper does not function) 518
Troubleshooting Code [E-9] 524
(The window washer does not function) 524
Troubleshooting Code [E-10] 527
(Lamps do not work properly) 527
Troubleshooting Code [E-11] 538
(The horn does not sound) 538
Troubleshooting Code [E-12] 540
(Defective the air conditioner) 540
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 549
Method of using troubleshooting chart 550
Failure code and cause table 552
H-1 554
The machine does not start 554
H-2 555
The travel speed is slow 555
H-3 556
The thrusting force is weak 556
H-4 557
Engine stalls when traveling or engine speed drops excessively 557
H-5 558
The gear is not shifted 558
H-6 559
The steering wheel does not turn 559
H-7 560
The steering wheel is heavy 560
H-8 561
Steering wheel shakes or jerks 561
H-9 561
Machine deviates naturally to one side when traveling 561
H-10 562
The brake does not work or does not work well 562
H-11 563
The brake is not released or is dragged 563
H-12 565
The lift arm does not rise or lower 565
H-13 566
The lift arm moves slowly or the lift arm rising force is insufficient 566
H-14 567
When rising, the lift arm comes to move slowly at specific height 567
H-15 567
The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) 567
H-16 567
Hydraulic drifts of the lift arm occur often 567
H-17 567
The lift arm wobbles during operation 567
H-18 568
When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily 568
H-19 569
The bucket does not tilt back 569
H-20 570
The bucket moves slowly or the tilting-back force is insufficient 570
H-21 571
The bucket comes to operate slowly in he midst of tilting-back 571
H-22 571
The bucket cylinder cannot hold down the bucket 571
H-23 571
Hydraulic drifts of the bucket occur often 571
H-24 572
The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) 572
H-25 572
When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily 572
H-26 572
The control levers of the lift arm and bucket do not move smoothly and heavy 572
TROUBLESHOOTING OF ENGINE (S MODE) 573
Method of using troubleshooting charts 574
S-7 Exhaust gas is black (incomplete combustion) 576
Starting performance is poor (Starting always takes time) 578
Engine does not start 580
(1) Engine does not turn 580
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) 581
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) 582
Engine does not pick up smoothly (Follow-up is poor) 583
Engine stops during operations 584
Engine does not rotate smoothly (Hunting) 585
Engine lacks output (or lacks power) 586
Exhaust smoke is black (Incomplete combustion) 587
Oil consumption is excessive (or exhaust smoke is blue) 588
Oil becomes contaminated quickly 589
Fuel consumption is excessive 590
Oil is in cooling water, or water spurts back, or water level goes down 591
Oil pressure caution lamp lights up (Drop in oil pressure) 592
Oil level rises (Water, fuel in oil) 593
Water temperature becomes too high (Overheating) 594
Abnormal noise is made 595
Vibration is excessive 596
30 DISASSEMBLY AND ASSEMBLY 597
Removal and installation of fuel injection pump assembly 612
Removal and installation of nozzle holder assembly 617
Removal and installation of cylinder head assembly 618
Removal and installation of engine 626
Removal and installation of radiator assembly 633
Removal and installation of air aftercooler assembly 634
Removal and installation of hydraulic oil cooler assembly 636
Removal and installation of cooling fan and fan motor assembly 638
Removal and installation of fuel tank assembly 639
Removal and installation of transfer assembly 641
Disassembly and assembly of transfer assembly 644
Removal and installation of parking brake assembly 663
Disassembly and assembly of parking brake assembly 665
Removal and installation of front axle assembly 670
Removal and installation of rear axle assembly 671
Disassembly and assembly of axle housing assembly 674
Disassembly and assembly of differential assembly 682
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 valve 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
How to read this manual 598
Precautions when performing operation 600
Special tool list 602
Sketches of special tools 605
90 OTHERS 761
HYDRAULIC CIRCUIT DIAGRAM 763
HYDRAULIC CIRCUIT DIAGRAM 765
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4) 767
(Machines equipped with ROPS cab) 767
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4) 769
ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4) 771
ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4) 773
ELECTRICAL CIRCUIT DIAGRAM 2/4 775
ELECTRICAL CIRCUIT DIAGRAM 3/4 777
ELECTRICAL CIRCUIT DIAGRAM 4/4 779

DESCRIPTION:

Komatsu WA200-5H WA200PT-5H Wheel Loader Shop Manual VEBM220100  – PDF DOWNLOAD

• MACHINE MODEL     SERIAL NUMBER
  WA200-5H                   H50051 and up
  WA200PT-5H               H60051 and up

G.B 18/12/24