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Komatsu WA200-5L, WA200PT-5L GALEO Wheel Loader Shop Manual CEBM013003 – PDF DOWNLOAD
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Komatsu WA200-5L, WA200PT-5L GALEO Wheel Loader Shop Manual
SERIAL NUMBERS:
WA200-5L A82001 and up
WA200PT-5L A89001 and up
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Description
Komatsu WA200-5L, WA200PT-5L GALEO Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA200-5L, WA200PT-5L GALEO Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA200-5L, WA200PT-5L GALEO
Serial Number: A82001 and up, A89001 and up
Book Code: CEBM013003
Language: English
Pages: 960
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA200-5L, WA200PT-5L GALEO Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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.
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’ to “Causes” are also included In this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA200-5L, WA200PT-5L GALEO Wheel Loader Shop Manual
COVER.................................................................................................... 1 FOREWORD................................................................................................. 2 CONTENTS............................................................................................. 2 SAFETY............................................................................................... 11 SAFETY NOTICE.................................................................................... 11 IMPORTANT SAFETY NOTICE...................................................................... 11 GENERAL PRECAUTIONS.......................................................................... 11 PREPARATIONS FOR WORK........................................................................ 11 PRECAUTIONS DURING WORK...................................................................... 11 GENERAL.............................................................................................. 13 HOW TO READ THE SHOP MANUAL.......................................................................... 14 VOLUMES.......................................................................................... 14 DISTRIBUTION AND UPDATING........................................................................ 14 FILING METHOD.................................................................................... 14 REVISED EDITION MARK............................................................................. 14 REVISIONS........................................................................................ 14 SYMBOLS.......................................................................................... 14 HOISTING INSTRUCTIONS................................................................................ 15 HOISTING......................................................................................... 15 WIRE ROPES....................................................................................... 15 COATING MATERIALS.................................................................................... 18 STANDARD TIGHTENING TORQUE........................................................................... 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS..................................................... 20 TIGHTENING TORQUE OF HOSE NUTS................................................................... 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.......................................................... 21 TIGHTENING TORQUE FOR FLARED NUTS................................................................ 21 ELECTRIC WIRE CODE................................................................................... 25 CLASSIFICATION BY THICKNESS...................................................................... 25 CLASSIFICATION BY COLOR AND CODE................................................................. 25 CONVERSION TABLES.................................................................................... 26 METHOD OF USING THE CONVERSION TABLE............................................................. 26 01 GENERAL............................................................................................... 33 GENERAL ASSEMBLY DRAWINGS............................................................................ 34 SPECIFICATIONS....................................................................................... 35 WEIGHT TABLE......................................................................................... 39 FLUID USE ACCORDING TO AMBIENT TEMPERATURE........................................................... 40 COOLANT SPECIFICATIONS........................................................................... 42 SUPERCOOLANT (AF-NAC)............................................................................ 42 10 STRUCTURE AND FUNCTION................................................................................ 43 ENGINE AND DRIVE SYSTEM MOUNTING..................................................................... 49 DRIVE SYSTEM DAMPER.................................................................................. 50 COOLING SYSTEM....................................................................................... 51 REVERSING FAN SYSTEM................................................................................. 52 REVERSING FAN MANIFOLD............................................................................... 53 PROPORTIONAL RELIEF VALVE............................................................................ 54 2-POSITION, 4-WAY SPOOL VALVE........................................................................ 55 FAN CONTROLLER....................................................................................... 56 POWER TRAIN.......................................................................................... 58 POWER TRAIN SYSTEM DIAGRAM........................................................................... 59 DRIVE SHAFT.......................................................................................... 61 HST HYDRAULIC PIPING DIAGRAM......................................................................... 62 HST PUMP............................................................................................. 63 OPERATION........................................................................................ 64 FLOW OF OIL...................................................................................... 65 HIGH-PRESSURE RELIEF VALVE....................................................................... 66 LOW-PRESSURE RELIEF VALVE........................................................................ 68 CHARGE PUMP...................................................................................... 69 SPEED-RELATED VALVE (DA VALVE)................................................................... 70 HIGH-PRESSURE CUT-OFF VALVE...................................................................... 71 HST MOTOR............................................................................................ 72 HST MOTOR 1...................................................................................... 72 HST MOTOR 2...................................................................................... 74 EP SERVO VALVE................................................................................... 76 HA SERVO VALVE................................................................................... 77 FORWARD-REVERSE SHUTTLE VALVE.................................................................... 78 TRANSFER............................................................................................. 79 OUTLINE.......................................................................................... 79 INPUT SHAFT PORTION.............................................................................. 82 OUTPUT SHAFT PORTION............................................................................. 84 CLUTCH OPERATION................................................................................. 87 LOW-SPEED MODE................................................................................... 88 HIGH-SPEED MODE.................................................................................. 89 CLUTCH SOLENOID VALVE................................................................................ 90 OPERATION........................................................................................ 90 AXLE................................................................................................. 91 FRONT AXLE....................................................................................... 91 REAR AXLE........................................................................................ 92 DIFFERENTIAL......................................................................................... 93 FRONT DIFFERENTIAL............................................................................... 93 REAR DIFFERENTIAL................................................................................ 95 OUTLINE.......................................................................................... 97 LIMITED SLIP DIFFENTIAL.............................................................................. 98 OPERATION........................................................................................ 99 WHEN TRAVELING IN A STRAIGHT LINE............................................................100 WHEN TURNING.................................................................................101 FINAL DRIVE..........................................................................................102 OUTLINE..........................................................................................103 AXLE MOUNTING AND CENTER HINGE PIN...................................................................104 OUTLINE..........................................................................................105 STEERING PIPING SYSTEM...............................................................................108 STEERING COLUMN......................................................................................109 PRIORITY VALVE.......................................................................................110 OUTLINE..........................................................................................111 OPERATION........................................................................................111 STRAIGHT TRAVEL..............................................................................111 STEERING WHEEL TURNED TO LEFT................................................................112 STEERING CYLINDER AT END OF STROKE...........................................................112 ORBIT-ROLL VALVE.....................................................................................113 OUTLINE..........................................................................................114 STRUCTURE........................................................................................114 OPERATION........................................................................................115 STEERING WHEEL AT NEUTRAL....................................................................115 STEERING WHEEL TURNED (TURNING LEFT).........................................................117 STEERING WHEEL STOPPED.......................................................................118 CONNECTION BETWEEN HAND PUMP AND SLEEVE......................................................119 ROLE OF CENTERING SPRING.....................................................................120 2-WAY RESTRICTOR VALVE...............................................................................121 FUNCTION.........................................................................................121 OPERATION........................................................................................121 CUSHION VALVE........................................................................................122 OUTLINE..........................................................................................122 FUNCTION.........................................................................................122 STEERING CYLINDER....................................................................................123 EMERGENCY STEERING PIPING............................................................................125 EMERGENCY STEERING VALVE.............................................................................126 OPERATION........................................................................................127 WHEN ENGINE AND STEERING PUMP ARE NORMAL.....................................................127 WHEN ENGINE OR STEERING PUMP IS ABNORMAL.....................................................128 BRAKE PIPING.........................................................................................129 BRAKE VALVE..........................................................................................130 OUTLINE..........................................................................................131 OPERATION........................................................................................131 WHEN BRAKE PEDAL IS PRESSED..................................................................131 WHEN BALANCED................................................................................132 WHEN BRAKE PEDAL IS RELEASED.................................................................133 INCHING VALVE....................................................................................134 OUTLINE......................................................................................134 CHARGE VALVE.........................................................................................135 FUNCTION.........................................................................................136 OPERATION........................................................................................137 WHEN OIL IS NOT SUPPLIED TO ACCUMULATOR......................................................137 WHEN OIL IS SUPPLIED TO ACCUMULATOR..........................................................137 WHEN INPUT PRESSURE TO VALVE RISES ABOVE SET PRESSURE........................................138 BRAKE ACCUMULATOR....................................................................................139 FUNCTION.........................................................................................139 SPECIFICATIONS...................................................................................139 SLACK ADJUSTER.......................................................................................140 FUNCTION.........................................................................................141 OPERATION........................................................................................141 WHEN BRAKE IS APPLIED........................................................................141 WHEN BRAKE IS RELEASED.......................................................................141 BRAKE................................................................................................142 OUTLINE..........................................................................................143 WHEN BRAKE IS APPLIED........................................................................143 WHEN BRAKE IS RELEASED.......................................................................143 PARKING BRAKE CONTROL................................................................................144 OUTLINE..........................................................................................144 PARKING BRAKE........................................................................................145 OUTLINE..........................................................................................145 HYDRAULIC PIPING.....................................................................................146 WA200-5L.........................................................................................146 WA200PT-5L.......................................................................................148 OUTLINE......................................................................................149 WORK EQUIPMENT LEVER LINKAGE.........................................................................150 WA200-5L.........................................................................................150 MULTI-FUNCTION JOYSTICK......................................................................150 STANDARD JOYSTICK............................................................................151 WA200PT-5L.......................................................................................152 MULTI-FUNCTION JOYSTICK......................................................................152 STANDARD JOYSTICK............................................................................153 HYDRAULIC TANK.......................................................................................154 SPECIFICATIONS...................................................................................155 BREATHER.........................................................................................155 PREVENTION OF NEGATIVE PRESSURE IN TANK......................................................155 PREVENTION OF RISE OF PRESSURE IN TANK.......................................................155 4-GEAR PUMP UNIT.....................................................................................156 OUTLINE..........................................................................................156 PPC CIRCUIT ACCUMULATOR..............................................................................158 OUTLINE..........................................................................................158 SPECIFICATIONS...................................................................................158 LOCK VALVE...........................................................................................158 OUTLINE..........................................................................................158 BYPASS VALVE.........................................................................................159 BOOM CYLINDER (WA200-5L AND WA200PT-5L)..........................................................159 OPERATION....................................................................................160 BUCKET CYLINDER (WA200PT-5L).....................................................................162 OPERATION........................................................................................163 QUICK COUPLER SOLENOID VALVE.........................................................................165 OUTLINE..........................................................................................165 E.C.S.S. VALVE.......................................................................................166 ECSS ACCUMULATOR.....................................................................................168 FUNCTION.........................................................................................168 SPECIFICATIONS...................................................................................168 HYDRAULIC PIPING OF COOLING SYSTEM...................................................................169 OUTLINE..........................................................................................169 COOLING FAN MOTOR....................................................................................170 SPECIFICATIONS...................................................................................170 FUNCTION.........................................................................................171 PRINCIPLE OF OPERATION.......................................................................171 WORK EQUIPMENT CONTROL VALVE.........................................................................172 2-SPOOL VALVE....................................................................................172 3-SPOOL VALVE....................................................................................175 RELIEF VALVE.................................................................................178 SAFETY-SUCTION VALVE.........................................................................179 SUCTION VALVE................................................................................180 OPERATION OF THE WORK EQUIPMENT CONTROL VALVE................................................181 WORK EQUIPMENT PPC VALVE.............................................................................187 MONO-LEVER TYPE..................................................................................187 OPERATION....................................................................................189 ATTACHMENT PPC VALVE.................................................................................192 OPERATION........................................................................................194 AT THE NEUTRAL POSITION......................................................................194 AT THE FINE CONTROL POSITION.................................................................194 AT FULL STROKE...............................................................................195 WORK EQUIPMENT LINKAGE...............................................................................196 WA200-5L.........................................................................................196 WA200PT-5L.......................................................................................198 BUCKET...............................................................................................200 CONTROL FOR BUCKET AND BOOM..........................................................................202 FOR WA200-5L.....................................................................................202 OUTLINE......................................................................................203 OPERATION OF PROXIMITY SWITCH................................................................204 FUNCTION OF PROXIMITY SWITCH.................................................................206 OPERATION OF BOOM KICK-OUT...................................................................207 FUNCTION OF PROXIMITY SWITCH.................................................................209 FOR WA200PT-5L...................................................................................210 OUTLINE..........................................................................................211 BUCKET POSITIONER OR FORK POSITIONER.........................................................211 BOOM KICK-OUT................................................................................211 DUMP SPEED CONTROL...........................................................................211 OPERATION OF PROXIMITY SWITCH....................................................................212 WHEN BUCKET IS TILTED........................................................................212 FUNCTION OF PROXIMITY SWITCH.................................................................214 WHEN LIFT ARM IS RAISED..........................................................................215 FUNCTION OF PROXIMITY SWITCH.................................................................217 WHEN BUCKET IS DUMPED............................................................................218 FUNCTION OF PROXIMITY SWITCH.................................................................219 WORK EQUIPMENT CYLINDER..............................................................................220 WA200-5L.........................................................................................220 LIFT CYLINDER................................................................................220 BUCKET CYLINDER..............................................................................220 WA200PT-5L.......................................................................................221 LIFT CYLINDER................................................................................221 BUCKET CYLINDER..............................................................................221 COUPLER PLUNGER..............................................................................221 AIR CONDITIONER......................................................................................223 AIR CONDITIONER PIPING...........................................................................223 MACHINE MONITORING SYSTEM............................................................................224 OUTLINE..........................................................................................224 NORMAL MODE......................................................................................224 SERVICE MODE.....................................................................................225 INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR...............................................227 STARTING AND LIGHTING........................................................................227 POWER SUPPLY AND NETWORK.....................................................................229 SENSING......................................................................................230 HST SAFETY CONTROL...........................................................................231 AUTOMATIC PREHEATING.........................................................................232 MACHINE MONITOR......................................................................................233 LIST OF ITEMS DISPLAYED ON MONITOR...............................................................234 SERVICE MODE FUNCTIONS...........................................................................240 OUTLINE......................................................................................240 OPERATING METHOD.............................................................................242 ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM........................................243 ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM.........................................246 REAL-TIME MONITOR FUNCTION...................................................................248 MAINTENANCE FUNCTIONS........................................................................251 FUNCTION OF SELECTING OPTIONAL DEVICE........................................................255 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)............................................................259 SYSTEM DIAGRAM...................................................................................259 CONTROL FUNCTION.................................................................................259 HST CONTROLLER.......................................................................................262 INPUT AND OUTPUT SIGNALS.........................................................................262 DIRECTIONAL SELECTOR SWITCH..........................................................................263 OUTLINE..........................................................................................263 FUNCTION.........................................................................................263 OPERATION........................................................................................264 WHEN TRAVEL DIRECTION IS CHANGED WITH DIRECTIONAL LEVER......................................264 WHEN DIRECTIONAL SELECTOR SWITCH IS SELECTED TO BE USED......................................264 WHEN TRAVEL DIRECTION IS CHANGED WITH DIRECTIONAL SELECTOR SWITCH............................264 WHEN DIRECTIONAL LEVER HAS PRIORITY..........................................................264 ENGINE STARTING CIRCUIT..............................................................................265 FUNCTION.........................................................................................265 OPERATION........................................................................................266 ENGINE STOP CIRCUIT..................................................................................267 OPERATION........................................................................................267 PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM)........................................................268 OUTLINE..........................................................................................268 OPERATION........................................................................................268 PARKING BRAKE CIRCUIT................................................................................269 OPERATION........................................................................................270 WHEN PARKING BRAKE LEVER IS RETURNED (ON o OFF)..................................................270 WHEN PARKING BRAKE LEVER IS PULLED (OFF to ON)...............................................271 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM..........................................................272 FUNCTION.........................................................................................272 COUPLER PLUNGER CONTROL SYSTEM.......................................................................273 WA200PT-5L.......................................................................................273 OUTLINE......................................................................................273 OPERATION....................................................................................273 SENSORS..............................................................................................274 ENGINE SPEED SENSOR..............................................................................274 FUNCTION.....................................................................................274 SPEED SENSOR.....................................................................................274 FUNCTION.....................................................................................274 ENGINE OIL PRESSURE SENSOR.......................................................................275 FUNCTION.....................................................................................275 FUEL LEVEL SENSOR................................................................................275 FUNCTION.....................................................................................275 COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR).............................................276 FUNCTION.....................................................................................276 COOLANT TEMPERATURE SENSOR (FOR PREHEATING)......................................................276 FUNCTION.....................................................................................276 AXLE OIL TEMPERATURE SENSOR......................................................................277 FUNCTION.....................................................................................277 HST OIL PRESSURE SENSOR..........................................................................277 FUNCTION.....................................................................................277 STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR..............................................278 FUNCTION.....................................................................................278 HST FILTER CLOGGING SENSOR.......................................................................278 FUNCTION.....................................................................................278 COOLANT LEVEL SENSOR.............................................................................279 FUNCTION.....................................................................................279 20 TESTING, ADJUSTING AND TROUBLESHOOTING................................................................281 STANDARD VALUE TABLE.................................................................................283 ENGINE...........................................................................................283 CHASSIS..........................................................................................284 SPECIAL TOOLS........................................................................................290 T-ADAPTER PROCEDURES AND KITS........................................................................293 ENGINE COMPONENTS....................................................................................294 MEASURING EXHAUST SMOKE..........................................................................294 MEASURING EXHAUST TEMPERATURE....................................................................294 ADJUSTING VALVE CLEARANCE........................................................................294 MEASURING COMPRESSION PRESSURE...................................................................294 MEASURING CRANKCASE PRESSURE.....................................................................294 MEASURING ENGINE OIL PRESSURE....................................................................294 MEASURING BOOST PRESSURE.........................................................................294 MEASURING FUEL PRESSURE..........................................................................294 ADJUSTING ENGINE SPEED SENSOR....................................................................294 BLEEDING AIR FROM FUEL SYSTEM....................................................................294 MEASURING ENGINE SPEED...........................................................................295 MEASURING (LOW AND HIGH IDLE)................................................................295 MEASURING HST STALL SPEED....................................................................296 MEASURING HYDRAULIC STALL....................................................................296 MEASURING FULL STALL SPEED...................................................................296 MEASURING, OPERATING FORCE OF ACCELERATOR PEDAL......................................................297 TESTING OPERATING FORCE..........................................................................297 OPERATING ANGLE OF PEDAL.........................................................................298 ADJUSTING ENGINE STOP SOLENOID.......................................................................299 ADJUSTING ENGINE SPEED SENSOR........................................................................300 REFRIGERENT COMPRESSOR BELT..........................................................................301 MEASURING DIRECTIONAL LEVER..........................................................................302 HST OIL PRESSURE.....................................................................................303 MEASURING........................................................................................303 ADJUSTING........................................................................................306 MEASURING CLUTCH CONTROL PRESSURE....................................................................308 STEERING WHEEL.......................................................................................309 MEASURING WHEEL END PLAY.........................................................................309 MEASURING OPERATING FORCE........................................................................309 MEASURING OPERATING TIME.........................................................................310 STEERING OIL PRESSURE................................................................................311 MEASURING MAIN RELIEF PRESSURE...................................................................311 ADJUSTING MAIN RELIEF PRESSURE...................................................................311 BLEEDING AIR FROM STEERING CIRCUIT...............................................................312 HYDRAULIC FAN........................................................................................313 MEASURING FAN SPEED..............................................................................313 MEASURING OIL PRESSURE...........................................................................314 MEASURING BRAKE PEDAL................................................................................316 BRAKE PEDAL LINKAGE..................................................................................317 MEASURING BRAKE PERFORMANCE..........................................................................318 ACCUMULATOR CHARGE PRESSURE..........................................................................319 MEASURING BRAKE OIL PRESSURE.........................................................................320 MEASURING WEAR ON BRAKE DISC.........................................................................322 BLEEDING AIR FROM BRAKE CIRCUIT......................................................................323 PARKING BRAKE PERFORMANCE............................................................................324 PARKING BRAKE LINKAGE................................................................................325 WORK EQUIPMENT CONTROL LEVER.........................................................................326 WORK EQUIPMENT PRESSURE..............................................................................327 WORK EQUIPMENT PPC OIL PRESSURE......................................................................328 TESTING AND ADJUSTING............................................................................328 BLEEDING AIR.....................................................................................330 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................331 BUCKET POSITIONER....................................................................................332 BOOM KICK-OUT........................................................................................333 CHECKING PROXIMITY SWITCH............................................................................334 CONNECTING T-ADAPTER TO HST CONTROLLER...............................................................335 SPECIAL FUNCTIONS OF MACHINE MONITOR.................................................................338 FLOW OF MODES AND FUNCTIONS..........................................................................339 PM CLINIC INSPECTION CHART...........................................................................356 TROUBLESHOOTING (GENERAL)............................................................................359 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................360 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................362 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................363 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT...............................................363 HANDLING CONTROL BOX.........................................................................368 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS..................................369 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.........................................370 CHECKS BEFORE TROUBLESHOOTING....................................................................372 USING TROUBLESHOOTING CHARTS.................................................................373 PHENOMENA CONSIDERED TO BE FAILURES..........................................................374 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................377 T-ADAPTER TABLE..................................................................................401 CONNECTOR TYPES AND MOUNTING LOCATIONS...........................................................404 CONNECTOR LAYOUT DRAWING.........................................................................410 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..................................................415 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...................................................416 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL............................................416 USER CODE MEMORY RETENTION FUNCTION..........................................................416 HST CONTROLLER SYSTEM DIAGRAM....................................................................417 TROUBLESHOOTING CODE DISPLAY.....................................................................419 ERROR CODE AND POSSIBLE CAUSE TABLE..........................................................419 FUSE SYSTEM CHECK................................................................................420 FUSE PANNEL CONNECTION TABLE.................................................................420 INFORMATION CONTAINED IN TESTING PROCEDURES......................................................421 CODE KEY TABLE...............................................................................422 ERROR CODE: [989F00].............................................................................423 TRANSMISSION PROTECTION ALERT (00)...........................................................423 ERROR CODE: [DDD7KX].............................................................................424 SPEEDOMETER SYSTEM INPUT SIGNAL OUT OF RANGE.................................................424 ERROR CODE: [DHH1KX].............................................................................427 HST OIL PRESSURE SIGNAL OUT OF RANGE.........................................................427 ERROR CODE: [DLE2LC].............................................................................429 ENGINE SPEED SENSOR OUT OF RANGE.............................................................429 ERROR CODE: [DLT3KA].............................................................................431 TRAVEL SPEED DOES NOT REGISTER ON SPEEDOMETER................................................431 ERROR CODE: [DW26KZ].............................................................................434 MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED......................................................434 ERROR CODE: [DX19KZ].............................................................................438 MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED......................................................438 ERROR CODE: [DX20KZ].............................................................................440 CLUTCH SOLENOID SYSTEM OPEN OR SHORTED.......................................................440 TROUBLESHOOTING CODE: [HST-1]....................................................................442 DEFECTIVE HST POWER CONTROLLER SOURCE........................................................442 TROUBLESHOOTING CODE: [HST-2]....................................................................446 TRAVEL SPEED RANGES DO NOT CHANGE............................................................446 TROUBLESHOOTING CODE: [HST-3]....................................................................450 TRACTION CONTROL FOR HST SYSTEM CANNOT BE CONTROLLED.........................................450 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE).........................................................453 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...................................................456 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL............................................456 USER CODE MEMORY RETENTION FUNCTION..........................................................456 MONITOR SYSTEM CIRCUIT DIAGRAM...................................................................457 TROUBLESHOOTING CODE DISPLAY.....................................................................461 ERROR CODE AND POSSIBLE CAUSE TABLE..........................................................461 FUSE SYSTEM CHECK................................................................................462 FUSE PANEL CONNECTION TABLE..................................................................462 INFORMATION CONTAINED IN TESTING PROCEDURES......................................................463 CODE KEY TABLE...............................................................................464 ERROR CODE: [15B0NX].............................................................................465 HST OIL FILTER SHOWING CLOGGED CONDITION.....................................................465 ERROR CODE: [2G42ZG].............................................................................467 LOW ACCUMULATOR OIL PRESSURE INDICATED.......................................................467 ERROR CODE: [989F00].............................................................................469 TRANSMISSION PROTECTION CAUTION INDICATED....................................................469 ERROR CODE: [989FN1].............................................................................470 HST OVERSPEED CONDITION......................................................................470 ERROR CODE: [AB00L6].............................................................................471 DEFECTIVE BATTERY CHARGING CIRCUIT...........................................................471 ERROR CODE: [AB00MA].............................................................................473 DEFECTIVE BATTERY CHARGING CIRCUIT...........................................................473 ERROR CODE: [B@BAZG].............................................................................475 ABNORMAL ENGINE OIL PRESSURE INDICATED.......................................................475 ERROR CODE: [B@BCNS].............................................................................477 ENGINE COOLANT INDICATING OVERHEAT CONDITION.................................................477 ERROR CODE: [B@BCZK].............................................................................479 ABNORMAL COOLANT LEVEL INDICATION............................................................479 ERROR CODE: [B@C7NS].............................................................................481 BRAKE COOLING OIL INDICATING OVERHEATING CONDITION...........................................481 ERROR CODE: [B@CRNS].............................................................................483 HST OIL SHOWING OVERHEATING CONDITION........................................................483 ERROR CODE: [D5ZHL6].............................................................................485 STARTING SWITCH “C” (IGN) INPUT FAILURE INDICATED............................................485 ERROR CODE: [DAF0KT].............................................................................487 CONTROLLER INTERNAL FAILURE).................................................................487 ERROR CODE: [DAJ0KR].............................................................................489 HST CONTROLLER COMMUNICATION FAILURE.........................................................489 ERROR CODE: [DD15LD].............................................................................491 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET..............................................491 ERROR CODE: [DD16LD].............................................................................493 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET..............................................493 ERROR CODE: [DD17LD].............................................................................495 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET..............................................495 ERROR CODE: [DD18LD].............................................................................497 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET..............................................497 ERROR CODE: [DDK3KB].............................................................................499 IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER................................................499 ERROR CODE: [DDS5L6].............................................................................501 DECREASED STEERING OIL PRESSURE..............................................................501 ERROR CODE: [DGE2KX].............................................................................503 ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE...............................................503 ERROR CODE: [DGE3KX].............................................................................505 ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE...............................................505 ERROR CODE: [DGH1KX].............................................................................507 HST OIL SHOWING OVERHEATING CONDITION........................................................507 ERROR CODE: [DGR4KA].............................................................................509 BRAKE COOLING OIL INDICATING SHORT CIRCUIT...................................................509 ERROR CODE: [DGR4KX].............................................................................511 BRAKE COOLING OIL INDICATING OPEN CIRCUIT....................................................511 ERROR CODE: [DHE4KA].............................................................................513 ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM.................................513 TROUBLESHOOTING CODE: [MON-1]....................................................................515 PARKING BRAKE INDICATOR LAMP DOES NOT WORK...................................................515 TROUBLESHOOTING CODE: [MON-2]....................................................................519 BRAKE OIL PRESSURE NOT INDICATING CORRECTLY..................................................519 TROUBLESHOOTING CODE: [MON-3]....................................................................521 ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY...............................................521 TROUBLESHOOTING CODE: [MON-4]....................................................................523 HST OIL TEMPERATURE NOT INDICATING CORRECTLY.................................................523 TROUBLESHOOTING CODE: [MON-5]....................................................................525 FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY..................................................525 TROUBLESHOOTING CODE: [MON-6]....................................................................527 ABNORMAL COOLANT LEVEL INDICATION............................................................527 TROUBLESHOOTING CODE: [MON-7]....................................................................529 STEERING OIL PRESSURE NOT READING CORRECTLY..................................................529 TROUBLESHOOTING CODE: [MON-8]....................................................................531 EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY........................................531 TROUBLESHOOTING CODE: [MON-9]....................................................................533 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY....................................533 TROUBLESHOOTING CODE: [MON-10]...................................................................535 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY....................................535 TROUBLESHOOTING CODE: [MON-11]...................................................................537 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY....................................537 TROUBLESHOOTING CODE: [MON-12]...................................................................539 MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY....................................539 TROUBLESHOOTING CODE: [MON-13]...................................................................541 ALARM BUZZER DOES NOT STOP OR REMAINS ON.....................................................541 TROUBLESHOOTING CODE: [MON-14]...................................................................543 FRONT WINDSHIELD WIPER DOES NOT WORK.........................................................543 REAR WINDSHIELD WIPER DOES NOT WORK..........................................................545 TROUBLESHOOTING CODE: [MON-15]...................................................................547 HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION...............................................547 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................551 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...................................................553 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL..........................................553 USER CODE MEMORY RETENTION FUNCTION..........................................................553 ELECTRICAL SYSTEM CIRCUIT DIAGRAM................................................................554 FUSE SYSTEM CHECK................................................................................560 FUSE PANEL CONNECTION TABLE..................................................................560 INFORMATION CONTAINED IN TESTING PROCEDURES......................................................561 CODE: (E-1)......................................................................................563 ENGINE WILL NOT CRANK........................................................................563 CODE: (E-2)......................................................................................566 THE ENGINE DOES NOT SHUT DOWN................................................................566 CODE: (E-3)......................................................................................568 COLD START PREHEATER DOES NOT WORK PROPERLY..................................................568 CODE: (E-4)......................................................................................571 PARKING BRAKE DOES NOT FUNCTION PROPERLY.....................................................571 CODE: (E-5)......................................................................................574 BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY..................................................574 CODE: (E-6)......................................................................................577 BUCKET LEVER FUNCTION NOT WORKING PROPERLY...................................................577 CODE: (E-7)......................................................................................580 FLOAT HOLD FUNCTION NOT WORKING PROPERLY.....................................................580 CODE: (E-8)......................................................................................583 FRONT WINDSHIELD WIPER DOES NOT WORK.........................................................583 CODE: (E-8)......................................................................................587 REAR WINDSHIELD WIPER DOES NOT WORK..........................................................587 CODE: (E-9)......................................................................................589 THE WINDOW WASHER DOES NOT WORK..............................................................589 CODE: (E-10).....................................................................................591 HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION...............................................591 CODE: (E-10).....................................................................................594 HEADLAMPS (LO BEAM) DO NOT FUNCTION..........................................................594 CODE: (E-10).....................................................................................597 HEADLAMPS (HI BEAM) DO NOT FUNCTION..........................................................597 CODE: (E-10).....................................................................................600 CLEARANCE LAMPS DO NOT FUNCTION..............................................................600 CODE: (E-10).....................................................................................603 TURN SIGNALS DO NOT FUNCTION.................................................................603 CODE: (E-10).....................................................................................606 WORK LAMPS DO NOT FUNCTION...................................................................606 CODE: (E-11).....................................................................................609 HORN DOES NOT SOUND..........................................................................609 CODE: (E-12).....................................................................................611 AIR CONDITIONER SYSTEM DOES NOT WORK.........................................................611 CODE: (E-12).....................................................................................614 AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED.........................................614 CODE: (E-12).....................................................................................618 AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED..........................................618 CODE: (E-12).....................................................................................622 CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS..........................................622 CODE: (E-12).....................................................................................624 CANNOT SWITCH VENT FUNCTIONS.................................................................624 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................627 METHOD OF USING TROUBLESHOOTING CHART............................................................629 FAILURE CODE AND CAUSE TABLE.....................................................................632 CODE: (H-1)......................................................................................635 THE MACHINE DOES NOT START...................................................................635 CODE: (H-2)......................................................................................636 THE TRAVEL SPEED IS SLOW.....................................................................636 CODE: (H-3)......................................................................................637 THE THRUST FORCE IS WEAK.....................................................................637 CODE: (H-4)......................................................................................638 ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY..............................................638 CODE: (H-5)......................................................................................639 THE GEARS DO NOT CHANGE SPEED RANGE..........................................................639 CODE: (H-6)......................................................................................640 THE STEERING WHEEL DOES NOT TURN.............................................................640 CODE: (H-7)......................................................................................641 STEERING WHEEL MOVEMENT IS HEAVY.............................................................641 CODE: (H-8)......................................................................................642 STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT..................................................642 CODE H-9.........................................................................................642 MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING..................................................642 CODE: (H-10).....................................................................................643 BRAKES DO NOT WORK OR WORKS POORLY...........................................................643 CODE: (H-11).....................................................................................644 BRAKES IS NOT RELEASING OR DRAGGED...........................................................644 CODE: (H-12).....................................................................................645 THE LIFT ARM DOES NOT RISE OR LOWER..........................................................645 CODE: (H-13).....................................................................................646 LIFT ARM MOVES SLOW OR RISING FORCE IS POOR..................................................646 CODE: (H-14).....................................................................................647 WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS...................................647 CODE: (H-15).....................................................................................647 THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES).......................647 CODE: (H-16).....................................................................................647 HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN.................................................647 CODE: (H-17).....................................................................................647 THE LIFT ARM WOBBLES DURING OPERATION........................................................647 CODE: (H-18).....................................................................................648 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY....648 CODE: (H-19).....................................................................................649 THE BUCKET DOES NOT TILT BACK................................................................649 CODE: (H-20).....................................................................................650 BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT..................................650 CODE: (H-21).....................................................................................651 THE BUCKET OPERATES SLOWLY IN TILTING-BACK...................................................651 CODE: (H-22).....................................................................................651 BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET..................................................651 CODE: (H-23).....................................................................................651 HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN..................................................651 CODE: (H-24).....................................................................................651 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)......651 CODE: (H-25).....................................................................................652 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY.......652 CODE: (H-26).....................................................................................652 CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY..............................652 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................653 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................654 (S-1) ENGINE STARTING PERFORMANCE IS POOR........................................................658 (S-2) ENGINE HAS STARTING PROBLEMS...............................................................660 ENGINE DOES NOT CRANK........................................................................660 ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK........................................661 SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START...........................................662 (S-3) ENGINE DOES NOT RUN SMOOTHLY...............................................................663 (S-4) ENGINE STOPS DURING OPERATIONS.............................................................664 (S-5) ENGINE SPEED HUNTS.........................................................................665 (S-6) ENGINE LACKS POWER.........................................................................666 (S-7) EXHAUST SMOKE IS BLACK.....................................................................667 (S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE......................................668 (S-9) OIL BECOMES CONTAMINATED QUICKLY...........................................................669 (S-10) FUEL CONSUMPTION IS EXCESSIVE.............................................................670 (S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR.....................................671 (S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP.......................................................672 (S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)............................................673 (S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)................................................674 (S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG............................................675 (S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING................................................676 30 DISASSEMBLY AND ASSEMBLY..............................................................................677 HOW TO READ THIS MANUAL..............................................................................680 REMOVAL AND INSTALLATION (DISASSEMBLY AND ASSEMBLY) OF ASSEMBLIES................................680 SPECIAL TOOLS................................................................................680 REMOVAL AND/OR DISASSEMBLY OF PARTS..........................................................680 INSTALLATION AND/OR ASSEMBLY OF PARTS........................................................681 SKETCHES OF SPECIAL TOOLS....................................................................681 PRECAUTIONS WHEN PERFORMING OPERATION................................................................682 SPECIAL TOOL LIST....................................................................................685 SKETCHES OF SPECIAL TOOLS............................................................................688 FUEL INJECTION PUMP ASSEMBLY.........................................................................695 SPECIAL TOOLS....................................................................................688 REMOVAL..........................................................................................695 INSTALLATION.....................................................................................698 BLEEDING AIR.................................................................................700 NOZZLE HOLDER ASSEMBLY...............................................................................701 SPECIAL TOOLS.................................................................................... 0 REMOVAL..........................................................................................701 INSTALLATION.....................................................................................702 CYLINDER HEAD ASSEMBLY...............................................................................703 SPECIAL TOOLS.................................................................................... 0 REMOVAL..........................................................................................703 INSTALLATION.....................................................................................710 ENGINE ASSEMBLY......................................................................................714 REMOVAL..........................................................................................714 INSTALLATION.....................................................................................721 RADIATOR ASSEMBLY....................................................................................723 REMOVAL..........................................................................................723 INSTALLATION.....................................................................................724 AIR AFTERCOOLER......................................................................................725 REMOVAL..........................................................................................725 INSTALLATION.....................................................................................726 HYDRAULIC OIL COOLER.................................................................................727 REMOVAL..........................................................................................727 INSTALLATION.....................................................................................729 COOLING FAN AND FAN MOTOR............................................................................730 REMOVAL..........................................................................................730 INSTALLATION.....................................................................................731 FUEL TANK............................................................................................732 REMOVAL..........................................................................................732 INSTALLATION.....................................................................................734 TRANSFER.............................................................................................735 REMOVAL..........................................................................................735 INSTALLATION.....................................................................................737 TRANSFER ASSEMBLY....................................................................................738 SPECIAL TOOLS.................................................................................... 0 DISASSEMBLY......................................................................................738 ASSEMBLY.........................................................................................749 PARKING BRAKE ASSEMBLY...............................................................................763 REMOVAL..........................................................................................763 INSTALLATION.....................................................................................764 DISASSEMBLY......................................................................................765 SPECIAL TOOLS.................................................................................... 0 ASSEMBLY.........................................................................................768 FRONT AXLE ASSEMBLY..................................................................................772 REMOVAL..........................................................................................772 INSTALLATION.....................................................................................774 REAR AXLE ASSEMBLY...................................................................................775 REMOVAL..........................................................................................775 INSTALLATION.....................................................................................777 AXLE HOUSING ASSEMBLY................................................................................779 SPECIAL TOOLS.................................................................................... 0 DISASSEMBLY......................................................................................779 ASSEMBLY.........................................................................................783 DIFFERENTIAL ASSEMBLY................................................................................790 SPECIAL TOOLS.................................................................................... 0 DISASSEMBLY......................................................................................790 ASSEMBLY.........................................................................................803 HST PUMP AND 4-GEAR PUMP ASSEMBLY....................................................................822 REMOVAL..........................................................................................822 INSTALLATION.....................................................................................825 HST PUMP ASSEMBLY....................................................................................826 DISASSEMBLY......................................................................................826 ASSEMBLY.........................................................................................838 HST MOTOR 1 ASSEMBLY.................................................................................855 REMOVAL..........................................................................................855 INSTALLATION.....................................................................................856 HST MOTOR 2 ASSEMBLY.................................................................................857 REMOVAL..........................................................................................857 INSTALLATION.....................................................................................858 HST MOTOR ASSEMBLY...................................................................................859 DISASSEMBLY......................................................................................859 ASSEMBLY.........................................................................................869 WORK EQUIPMENT CONTROL VALVE ASSEMBLY................................................................880 REMOVAL..........................................................................................880 INSTALLATION.....................................................................................881 TRAVEL DAMPER VALVE ASSEMBLY.........................................................................882 REMOVAL..........................................................................................882 INSTALLATION.....................................................................................883 HYDRAULIC TANK.......................................................................................884 REMOVAL..........................................................................................884 INSTALLATION.....................................................................................886 WORK EQUIPMENT.......................................................................................887 REMOVAL..........................................................................................887 INSTALLATION.....................................................................................890 PROCEDURE FOR INSTALLING BUCKET LINK AND PIN.....................................................890 PROCEDURE FOR INSTALLING BUCKET HINGE PIN........................................................891 PROCEDURE FOR INSTALLING BUCKET CYLINDER PIN (ON ROD SIDE).......................................891 PROCEDURE FOR INSTALLING BOOM CYLINDER PIN (ON ROD SIDE).........................................892 PROCEDURE FOR INSTALLING BOOM PIN (ON FRAME SIDE)................................................893 PROCEDURE FOR INSTALLING BUCKET LINK PIN.........................................................893 HYDRAULIC CYLINDER ASSEMBLY..........................................................................895 SPECIAL TOOLS.................................................................................... 0 DISASSEMBLY......................................................................................895 ASSEMBLY.........................................................................................898 OPERATOR'S CAB ASSEMBLY..............................................................................904 SPECIAL TOOLS.................................................................................... 0 REMOVAL..........................................................................................904 INSTALLATION.....................................................................................909 OPERATOR'S CAB GLASS.................................................................................910 SPECIAL TOOLS.................................................................................... 0 REMOVAL..........................................................................................910 INSTALLATION.....................................................................................911 COATING MATERIALS................................................................................919 CENTER HINGE PIN.....................................................................................920 REMOVAL..........................................................................................920 INSTALLATION.....................................................................................926 COUNTERWEIGHT........................................................................................931 REMOVAL..........................................................................................931 INSTALLATION.....................................................................................932 AIR CONDITIONER UNIT ASSEMBLY........................................................................933 SPECIAL TOOLS.................................................................................... 0 REMOVAL..........................................................................................933 INSTALLATION.....................................................................................936 AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................937 SPECIAL TOOLS.................................................................................... 0 REMOVAL..........................................................................................937 INSTALLATION.....................................................................................942 MONITOR PANEL........................................................................................938 REMOVAL..........................................................................................938 INSTALLATION.....................................................................................942 90 OTHERS................................................................................................943 HYDRAULIC CIRCUIT DIAGRAM............................................................................944 ELECTRICAL CIRCUIT DIAGRAM...........................................................................946 FLOOR HARNESS....................................................................................946 MONITOR CIRCUIT..............................................................................946 CAB HARNESS..................................................................................947 TO FRONT AND BULK HEAD HARNESS...............................................................948 TO REAR AND HST HARNESS......................................................................949 AIR CONDITIONER RELAY HARNESS................................................................950 TO HST CONTROLLER AND WORK LAMPS.............................................................951 VARIABLE SHIFT CONTROL.......................................................................952 SWITCHES.....................................................................................953 HST AND BULK HEAD HARNESS........................................................................954 GRILL AND ENGINE HARNESS.........................................................................955 REAR AND POWER SUPPLY HARNESS....................................................................956 CAB, EMERGENCY STEERING AND MULTI-FUNCTION HARNESS...............................................957 FRONT HARNESS....................................................................................958 REVERSING FAN WIRING DIAGRAM.....................................................................959 PROPOSAL FOR MANUAL OR CSS REVISION......................................................................960
KOMATSU WA200-5L, WA200PT-5L GALEO WHEEL LOADER SHOP MANUAL CEBM013003 – PDF DOWNLOAD:
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