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Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual 70001 and up – PDF DOWNLOAD
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Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual
SERIAL NUMBERS :
WA200- 70001 and up
WA200PZ-70001 and up
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Description
Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual 70001 and up
FILE DETAILS:
Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA200-6, WA200PZ-6
Serial Number: 70001 and up
Book Code: SEN03862-02
Language: English
Pages: 1292
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual
COVER ................................................................................................................................ 1 00 INDEX AND FOREWORD................................................................................................................. 0 100 Index......................................................................................................................... 2 Composition of shop manual.................................................................................................... 3 Table of contents............................................................................................................. 5 200 FOREWORD AND GENERAL INFORMATION.............................................................................................. 16 SAFETY NOTICE................................................................................................................. 17 HOW TO READ THE SHOP MANUAL................................................................................................... 22 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................. 24 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT........................................................................ 26 HANDLING OF CONNECTORS NEWLY USED FOR ENGINES................................................................................. 35 HOW TO READ ELECTRIC WIRE CODE................................................................................................ 38 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................................... 41 METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER................................................................. 44 STANDARD TIGHTENING TORQUE TABLE.............................................................................................. 47 CONVERSION TABLE.............................................................................................................. 51 01 SPECIFICATION...................................................................................................................... 0 100 SPECIFICATION AND TECHNICAL DATA.............................................................................................. 58 SPECIFICATION DIMENSION DRAWING............................................................................................... 60 SPECIFICATIONS................................................................................................................ 61 WEIGHT TABLE.................................................................................................................. 65 TABLE OF FUEL, COOLANT AND LUBRICANTS......................................................................................... 67 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....................................................................................... 0 100 ENGINE AND COOLING SYSTEM..................................................................................................... 70 ENGINE MOUNT AND TRANSFER MOUNT............................................................................................... 71 DAMPER........................................................................................................................ 72 COOLING SYSTEM................................................................................................................ 73 COOLING SYSTEM HYDRAULIC PIPING DIAGRAM....................................................................................... 74 COOLING FAN MOTOR............................................................................................................. 76 200 POWER TRAIN................................................................................................................... 86 POWER TRAIN................................................................................................................... 88 POWER TRAIN SYSTEM DIAGRAM.................................................................................................... 89 DRIVE SHAFT................................................................................................................... 91 HST HYDRAULIC PIPING DIAGRAM.................................................................................................. 92 HST PUMP...................................................................................................................... 93 HST MOTOR..................................................................................................................... 101 TRANSFER...................................................................................................................... 107 CLUTCH SOLENOID VALVE......................................................................................................... 118 AXLE.......................................................................................................................... 119 DIFFERENTIAL.................................................................................................................. 121 TORQUE PROPORTIONING.......................................................................................................... 126 LIMITED SLIP DIFFERENTIAL..................................................................................................... 129 FINAL DRIVE................................................................................................................... 133 300 STEERING SYSTEM............................................................................................................... 138 STEERING PIPING DIAGRAM....................................................................................................... 140 STEERING COLUMN............................................................................................................... 141 PRIORITY VALVE................................................................................................................ 142 ORBIT-ROLL VALVE.............................................................................................................. 145 2-WAY RESTRICTOR VALVE........................................................................................................ 153 CUSHION VALVE................................................................................................................. 154 STEERING CYLINDER............................................................................................................. 155 EMERGENCY STEERING PIPING DIAGRAM............................................................................................. 157 EMERGENCY STEERING VALVE...................................................................................................... 158 STEERING RELIEF VALVE......................................................................................................... 161 400 BRAKE SYSTEM.................................................................................................................. 164 BRAKE PIPING DIAGRA........................................................................................................... 166 CHARGE VALVE.................................................................................................................. 167 BRAKE VALVE................................................................................................................... 171 INCHING VALVE................................................................................................................. 175 ACCUMULATOR (FOR BRAKE)....................................................................................................... 176 SLACK ADJUSTER................................................................................................................ 177 BRAKE......................................................................................................................... 179 PARKING BRAKE CONTROL......................................................................................................... 184 PARKING BRAKE................................................................................................................. 185 500 UNDERCARRIAGE AND FRAME....................................................................................................... 188 AXLE MOUNT AND CENTER HINGE PIN............................................................................................... 189 TIRES......................................................................................................................... 194 600 HYDRAULIC SYSTEM.............................................................................................................. 196 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM....................................................................................... 197 WORK EQUIPMENT CONTROL LEVER LINKAGE.......................................................................................... 201 HYDRAULIC TANK................................................................................................................ 205 4-GEAR PUMP................................................................................................................... 207 WORK EQUIPMENT CONTROL VALVE ................................................................................................. 210 PPC VALVE..................................................................................................................... 234 LOCK VALVE.................................................................................................................... 249 ACCUMULATOR (FOR PPC CIRCUIT)................................................................................................. 250 BYPASS VALVE.................................................................................................................. 251 QUICK COUPLER SOLENOID VALVE.................................................................................................. 254 ECSS VALVE.................................................................................................................... 255 ACCUMULATOR (FOR ECSS)........................................................................................................ 257 700 WORK EQUIPMENT................................................................................................................ 260 WORK EQUIPMENT LINKAGE........................................................................................................ 261 BUCKET........................................................................................................................ 265 BUCKET POSITIONER AND BOOM KICK-OUT........................................................................................... 269 WORK EQUIPMENT CYLINDER....................................................................................................... 282 800 CAB AND ITS ATTACHMENTS....................................................................................................... 286 CAB........................................................................................................................... 288 AIR CONDITIONER............................................................................................................... 289 910 ELECTRICAL SYSTEM, PART 1..................................................................................................... 302 MACHINE MONITOR SYSTEM........................................................................................................ 303 MACHINE MONITOR............................................................................................................... 307 920 ELECTRICAL SYSTEM, PART 2..................................................................................................... 330 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)..................................................................................... 331 HST CONTROLLER................................................................................................................ 347 ECSS SYSTEM................................................................................................................... 349 KOMTRAX SYSTEM................................................................................................................ 351 ENGINE STARTING CIRCUIT....................................................................................................... 353 ENGINE STOPPING CIRCUIT....................................................................................................... 355 PREHEATING CIRCUIT............................................................................................................ 356 ENGINE OUTPUT DERATING FUNCTION............................................................................................... 357 AUTOMATIC WARM-UP FUNCTION.................................................................................................... 357 PARKING BRAKE CIRCUIT......................................................................................................... 358 COUPLER PLUNGER CONTROL SYSTEM................................................................................................ 361 MULTI-FUNCTION KNOB........................................................................................................... 362 MAX. TRACTION SWITCH.......................................................................................................... 363 SENSOR........................................................................................................................ 364 20 STANDARD VALUE TABLE............................................................................................................... 0 100 STANDARD SERVICE VALUE TABLE.................................................................................................. 372 STANDARD SERVICE VALUE TABLE FOR ENGINE....................................................................................... 373 STANDARD SERVICE VALUE TABLE FOR CHASSIS...................................................................................... 374 30 TESTING AND ADJUSTING.............................................................................................................. 0 110 TESTING AND ADJUSTING, PART 1................................................................................................. 382 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................. 383 Sketches of special tools..................................................................................................... 388 Measuring engine speed........................................................................................................ 389 Measuring exhaust gas color................................................................................................... 391 ADJUSTING VALVE CLEARANCE..................................................................................................... 392 MEASURING COMPRESSION PRESSURE................................................................................................ 394 MEASURING BLOW-BY PRESSURE.................................................................................................... 397 TESTING ENGINE OIL PRESSURE................................................................................................... 398 MEASURING INTAKE AIR (BOOST) PRESSURE......................................................................................... 399 HANDLING FUEL SYSTEM EQUIPMENT................................................................................................ 401 RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM.................................................................................... 401 MEASURING FUEL PRESSURE....................................................................................................... 402 MEASURING FUEL RETURN RATE AND LEAKAGE........................................................................................ 404 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................ 408 Checking leakage in fuel system............................................................................................... 409 Handling cylinder cut-out mode operation...................................................................................... 410 Handling no-injection cranking operation...................................................................................... 410 HANDLING CONTROLLER VOLTAGE CIRCUIT........................................................................................... 411 CHECK OF MUFFLER AND MUFFLER STACK FOR LOOSENESS AND DAMAGE................................................................... 411 CHECK OF MUFFLER FUNCTION..................................................................................................... 412 CHECK OF INSTALLED CONDITION OF CYLINDER HEAD AND MANIFOLDS................................................................... 412 CHECK OF ENGINE PIPING FOR DAMAGE AND LOOSENESS............................................................................... 413 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................................................. 413 REPLACING ALTERNATOR BELT..................................................................................................... 414 120 TESTING AND ADJUSTING, PART 2................................................................................................. 416 CHECKING OPERATING FORCE OF ACCELERATOR PEDAL................................................................................. 418 CHECKING DIRECTIONAL LEVER.................................................................................................... 419 TESTING AND ADJUSTING HST OIL PRESSURE........................................................................................ 420 TESTING CLUTCH CONTROL PRESSURE............................................................................................... 424 TESTING AND ADJUSTING STEERING WHEEL.......................................................................................... 425 TESTING AND ADJUSTING STEERING OIL PRESSURE................................................................................... 427 BLEEDING AIR FROM STEERING CIRCUIT............................................................................................ 429 TESTING HYDRAULIC FAN......................................................................................................... 430 MEASURING BRAKE PEDAL......................................................................................................... 432 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE..................................................................................... 433 MEASURING BRAKE PERFORMANCE................................................................................................... 434 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE............................................................................. 435 TESTING WHEEL BRAKE OIL PRESSURE.............................................................................................. 437 TESTING WEAR OF BRAKE DISC.................................................................................................... 440 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT......................................................................................... 441 RELEASING RESIDUAL PRESSURE IN BRAKE ACCUMULATOR CIRCUIT...................................................................... 442 TESTING PARKING BRAKE PERFORMANCE............................................................................................. 443 TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE............................................................................. 444 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.......................................................................... 445 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE....................................................................... 446 TESTING WORK EQUIPMENT PPC OIL PRESSURE....................................................................................... 447 BLEEDING AIR FROM HYDRAULIC CIRCUIT........................................................................................... 449 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................. 450 TESTING AND ADJUSTING BUCKET POSITIONER....................................................................................... 451 TESTING AND ADJUSTING OF BOOM KICK-OUT SWITCH................................................................................. 453 CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP................................................................................ 454 PROCEDURE FOR TESTING DIODES.................................................................................................. 455 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM...................................................................... 457 STARTING KOMTRAX TERMINAL OPERATIONS.......................................................................................... 461 INDICATOR LAMPS OF KOMTRAX TERMINAL........................................................................................... 465 130 TESTING AND ADJUSTING, PART 3................................................................................................. 470 ADJUSTING MACHINE MONITOR..................................................................................................... 471 ADJUSTING REPLACED, REASSEMBLED OR ADDED SENSOR, CONTROLLER, ETC. WITH MACHINE MONITOR........................................ 472 SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS)................................................................................... 474 PM CLINIC INSPECTION CHART.................................................................................................... 528 40 TROUBLESHOOTING.................................................................................................................... 0 100 FAILURE CODE TABLE AND FUSE LOCATIONS......................................................................................... 532 FAILURE CODES TABLE........................................................................................................... 533 FUSE LOCATIONS................................................................................................................ 539 200 General information on troubleshooting........................................................................................ 544 Points to remember when troubleshooting....................................................................................... 545 Sequence of events in troubleshooting......................................................................................... 546 Testing before troubleshooting................................................................................................ 547 Classification and procedures of troubleshooting.............................................................................. 548 Information contained in troubleshooting table................................................................................ 551 Connection table for connector pin numbers.................................................................................... 553 T- branch box and T- branch adapter table..................................................................................... 589 310 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1..................................................................... 594 FAILURE CODE [2G40GZ] BRAKE: OIL PRESSURE REDUCTION........................................................................... 595 FAILURE CODE [6091NX] HST FILTER: CLOGGING.................................................................................... 597 FAILURE CODE [989FN1] TRAVEL SPEED: OVERRUN ALARM............................................................................. 598 FAILURE CODE [AB00L6] ALTERNATOR R SYSTEM: HOT SHORT.......................................................................... 599 FAILURE CODE [AB00MA] ALTERNATOR R SYSTEM: GROUND FAULT/DISCONNECTION CHARGE/LOW CHARGE VOLTAGE............................... 601 FAILURE CODE [B@BAZG] ENGINE: OIL PRESSURE REDUCTION.......................................................................... 603 FAILURE CODE [B@BCNS] ENGINE: OVERHEAT........................................................................................ 604 FAILURE CODE [B@BCZK] ENGINE: LOW COOLANT LEVEL............................................................................... 605 FAILURE CODE [B@C6NS] FRONT BRAKE: HIGH OIL TEMPERATURE....................................................................... 607 FAILURE CODE [B@CRNS] HST: HIGH OIL TEMPERATURE............................................................................... 608 320 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2..................................................................... 610 FAILURE CODE [CA111] ABNORMALITY IN ENGINE CONTROLLER......................................................................... 612 FAILURE CODE [CA115] ENGINE NE OR BKUP SPEED SENSOR ERROR..................................................................... 613 FAILURE CODE [CA122] CHARGE PRESSURE SENSOR HIGH ERROR........................................................................ 615 FAILURE CODE [CA123] CHARGE PRESSURE SENSOR LOW ERROR......................................................................... 617 FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR............................................................................... 619 FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR................................................................................ 621 FAILURE CODE [CA144] COOLANT SENSOR HIGH ERROR................................................................................ 623 FAILURE CODE [CA145] COOLANT SENSOR LOW ERROR................................................................................. 625 FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR HIGH ERROR..................................................................... 627 FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR LOW ERROR...................................................................... 629 FAILURE CODE [CA155] DERATING OF SPEED BY ABNORMALLY HIGH CHARGE TEMPERATURE.................................................. 631 FAILURE CODE [CA187] SENSOR POWER SUPPLY 2 LOW ERROR.......................................................................... 633 FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR HIGH ERROR................................................................... 635 FAILURE CODE [CA222] ATMOSPHERIC SENSOR LOW ERROR............................................................................. 637 FAILURE CODE [CA227] SENSOR POWER SUPPLY 2 HIGH ERROR......................................................................... 639 FAILURE CODE [CA234] ENGINE OVERSPEED......................................................................................... 640 FAILURE CODE [CA238] NE SPEED SENSOR POWER SUPPLY ERROR....................................................................... 641 FAILURE CODE [CA271] IMV (IMA) SHORT CIRCUIT.................................................................................. 642 FAILURE CODE [CA272] IMV (IMA) DISCONNECTION.................................................................................. 643 FAILURE CODE [CA322] INJECTOR #1 OPEN/SHORT ERROR............................................................................. 645 FAILURE CODE [CA324] INJECTOR #3 OPEN/SHORT ERROR............................................................................. 647 FAILURE CODE [CA331] INJECTOR #2 OPEN/SHORT ERROR............................................................................. 649 FAILURE CODE [CA332] INJECTOR #4 OPEN/SHORT ERROR............................................................................. 651 FAILURE CODE [CA342] CALIBRATION CODE INCONSISTENCY........................................................................... 653 FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR............................................................................ 655 FAILURE CODE [CA352] SENSOR POWER SUPPLY 1 LOW ERROR.......................................................................... 657 FAILURE CODE [CA386] SENSOR POWER SUPPLY 1 HIGH ERROR......................................................................... 659 330 Troubleshooting by failure code (Display of code), Part 3..................................................................... 662 Failure code [CA428] Abnormally high level in water sensor.................................................................... 665 Failure code [CA429] Abnormally low level in water sensor..................................................................... 667 Failure code [CA431] Idle validation switch error............................................................................. 669 Failure code [CA432] Idle validation action error............................................................................. 673 Failure code [CA435] Engine oil pressure switch error......................................................................... 677 Failure code [CA441] Battery voltage low error................................................................................ 678 Failure code [CA442] Battery voltage high error............................................................................... 681 Failure code [CA449] Common rail pressure high error 2........................................................................ 683 Failure code [CA451] Common rail pressure sensor high error................................................................... 685 Failure code [CA452] Common rail pressure sensor low error.................................................................... 687 Failure code [CA488] Derating of torque by abnormally high charge temperature................................................. 689 Failure code [CA553] Common rail pressure high error 1........................................................................ 690 Failure code [CA559] Supply pump pressure very low error...................................................................... 691 Failure code [CA689] Engine Ne speed sensor error............................................................................. 693 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 695 Failure code [CA757] All continuous data lost error........................................................................... 696 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 699 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 701 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 703 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 705 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 707 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 709 Failure code [CA2555] Intake heater relay disconnection error................................................................. 711 Failure code [CA2556] Intake heater relay short circuit error................................................................. 713 340 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4..................................................................... 716 FAILURE CODE [D160KY] BACKUP ALARM/LAMP RELAY 1 CIRCUIT: HOT SHORT............................................................ 717 FAILURE CODE [D192KY] ECSS SOLENOID RELAY: HOT SHORT.......................................................................... 719 FAILURE CODE [D1B0KA] HST SAFETY RELAY: DISCONNECTION......................................................................... 721 FAILURE CODE [D1B0KB] HST SAFETY RELAY: GROUND FAULT.......................................................................... 723 FAILURE CODE [D1B0KY] HST SAFETY RELAY: HOT SHORT............................................................................. 725 FAILURE CODE [D5ZHL6] IGN C SYSTEM: GROUND FAULT/DISCONNECTION................................................................ 727 FAILURE CODE [DAF3KK] UNSW POWER SUPPLY: GROUND FAULT/DISCONNECTION........................................................... 729 FAILURE CODE [DAFRKR] MACHINE MONITOR CAN-NET SIGNAL: DISCONNECTION........................................................... 731 FAILURE CODE [DAJ0KK] HST CONTROLLER POWER SUPPLY: LOW VOLTAGE................................................................ 735 FAILURE CODE [DAJ0KT] HST CONTROLLER MEMORY (EEPROM): ABNORMALITY............................................................. 737 FAILURE CODE [DAJ1L4] HST CONTROLLER MAIN POWER LINE: DISCONNECTION/GROUND FAULT.............................................. 739 FAILURE CODE [DAJ1L6] HST CONTROLLER MAIN POWER LINE: HOT SHORT............................................................... 741 FAILURE CODE [DAJ2KK] CONTROLLER SOLENOID POWER SUPPLY: LOW VOLTAGE........................................................... 743 FAILURE CODE [DAJ2L3] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: HOT SHORT IN WIRING HARNESS.............................. 745 FAILURE CODE [DAJ2L4] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: DISCONNECTION/GROUND FAULT............................... 747 FAILURE CODE [DAJ5KX] SENSOR 5V POWER SUPPLY: OUT OF OUTPUT RANGE............................................................. 749 FAILURE CODE [DAJ9KQ] HST CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS................................. 751 FAILURE CODE [DAJRKR] HST CONTROLLER CAN-NET SIGNAL: DISCONNECTION............................................................ 752 FAILURE CODE [DAJRMA] HST CONTROLLER: DISAGREEMENT IN OPTION SELECTION........................................................ 758 350 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5..................................................................... 760 FAILURE CODE [DB2RKR] ENGINE CONTROLLER CAN-NET: DISCONNECTION IN SIGNAL LINE................................................. 761 FAILURE CODE [DD1NL4] FAN AUTOMATIC REVERSE SWITCH SIGNAL: ABNORMALITY........................................................ 767 FAILURE CODE [DD1NLD] FAN REVERSE SWITCH SIGNAL: ABNORMALITY.................................................................. 769 FAILURE CODE [DDB6KA] PARKING BRAKE SWITCH A: DISCONNECTION/HOT SHORT......................................................... 771 FAILURE CODE [DDB6KB] PARKING BRAKE SWITCH B: GROUND FAULT.................................................................... 773 FAILURE CODE [DDB6KZ] PARKING BRAKE SWITCH (BOTTOM SWITCH) OR PARKING BRAKE REMINDER SWITCH (INTERMEDIATE SWITCH): TROUBLE.... 775 FAILURE CODE [DDB6L0] PARKING BRAKE SWITCH A: GROUND FAULT.................................................................... 777 FAILURE CODE [DDB6L4] PARKING BRAKE SWITCH B: DISCONNECTION/HOT SHORT......................................................... 779 FAILURE CODE [DDD7KX] TRAVEL SPEED CONTROL DIAL SIGNAL: DISCONNECTION/GROUND FAULT............................................ 781 FAILURE CODE [DDD7KY] TRAVEL SPEED CONTROL DIAL SIGNAL: HOT SHORT............................................................. 783 FAILURE CODE [DDE5MA] EMERGENCY STEERING OPERATION SWITCH: DISCONNECTION...................................................... 785 FAILURE CODE [DDK3KA] DIRECTIONAL SELECTOR SWITCH: DISCONNECTION/HOT SHORT.................................................... 787 FAILURE CODE [DDK3KB] DIRECTIONAL SELECTOR SWITCH: GROUND FAULT............................................................... 789 FAILURE CODE [DDK6KA] FNR LEVER: DISCONNECTION/GROUND FAULT................................................................... 791 FAILURE CODE [DDK6KY] FNR LEVER: HOT SHORT.................................................................................... 795 FAILURE CODE [DDS5L6] STEERING: LOW OIL PRESSURE (OPERATION OF EMERGENCY STEERING)............................................ 797 360 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6..................................................................... 800 FAILURE CODE [DF10KA] TRAVEL SPEED RANGE SELECTOR SWITCH: DISCONNECTION/GROUND FAULT.......................................... 801 FAILURE CODE [DF10KB] TRAVEL SPEED RANGE SELECTOR SWITCH: HOT SHORT........................................................... 805 FAILURE CODE [DGH1KX] HST OIL TEMPERATURE SENSOR: GROUND FAULT................................................................ 807 FAILURE CODE [DGR2KB] BRAKE OIL TEMPERATURE SENSOR: GROUND FAULT.............................................................. 808 FAILURE CODE [DGR2KZ] BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION/HOT SHORT................................................... 809 FAILURE CODE [DHH1KX] HST OIL PRESSURE SENSOR: DISCONNECTION/GROUND FAULT..................................................... 811 FAILURE CODE [DHH1KY] HST OIL PRESSURE SENSOR: HOT SHORT...................................................................... 813 FAILURE CODE [DHTCL6] HST FILTER CLOGGING SENSOR: FUNCTIONAL DEFECT........................................................... 815 FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION/HOT SHORT.............................................................. 817 FAILURE CODE [DLT3KX] TRAVEL SPEED SENSOR B: ABNORMALITY...................................................................... 819 FAILURE CODE [DLT4KX] TRAVEL SPEED SENSOR A: ABNORMALITY...................................................................... 823 FAILURE CODE [DLT4LC] TRAVEL SPEED SENSOR A & B: ABNORMALITY.................................................................. 825 FAILURE CODE [DV00KY] ALARM BUZZER: HOT SHORT................................................................................. 827 FAILURE CODE [DW26KA] MOTOR 2 SOLENOID: DISCONNECTION/GROUND FAULT............................................................ 829 FAILURE CODE [DW26KY] MOTOR 2 SOLENOID: HOT SHORT............................................................................. 831 FAILURE CODE [DW7BKY] FAN REVERSE SOLENOID CIRCUIT: HOT SHORT................................................................. 833 FAILURE CODE [DW7BKZ] FAN REVERSE SOLENOID CIRCUIT: DISCONNECTION/GROUND FAULT................................................ 835 370 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 7..................................................................... 838 FAILURE CODE [DX16KA] FAN EPC SOLENOID: DISCONNECTION......................................................................... 839 FAILURE CODE [DX16KB] FAN EPC SOLENOID: GROUND FAULT.......................................................................... 840 FAILURE CODE [DX16KY] FAN EPC SOLENOID: HOT SHORT............................................................................. 841 FAILURE CODE [DX19KA] MOTOR 1 SOLENOID: DISCONNECTION......................................................................... 843 FAILURE CODE [DX19KB] MOTOR 1 SOLENOID: GROUND FAULT.......................................................................... 845 FAILURE CODE [DX19KY] MOTOR 1 SOLENOID: HOT SHORT............................................................................. 847 FAILURE CODE [DX20KA] CLUTCH EPC SOLENOID: DISCONNECTION...................................................................... 849 FAILURE CODE [DX20KB] CLUTCH EPC SOLENOID: GROUND FAULT....................................................................... 851 FAILURE CODE [DX20KY] CLUTCH EPC SOLENOID: HOT SHORT.......................................................................... 853 FAILURE CODE [DXH7KB] REVERSE SOLENOID: GROUND FAULT.......................................................................... 855 FAILURE CODE [DXH7KZ] REVERSE SOLENOID: DISCONNECTION/HOT SHORT............................................................... 857 FAILURE CODE [DXH8KB] FORWARD SOLENOID: GROUND FAULT.......................................................................... 859 FAILURE CODE [DXH8KZ] FORWARD SOLENOID: DISCONNECTION/HOT SHORT............................................................... 861 FAILURE CODE [J141N1] STEERING PUMP: OVERRUN ALARM............................................................................ 863 FAILURE CODE [M100N1] HST PUMP: OVERRUN ALARM................................................................................. 863 FAILURE CODE [M400N1] MOTOR 1: OVERRUN ALARM.................................................................................. 864 400 Troubleshooting of electrical system(E-mode).................................................................................. 866 E-1 Engine does not start..................................................................................................... 868 E-2. Preheater does not operate normally...................................................................................... 875 E-3 Travel speed is low or high............................................................................................... 879 E-4 ECSS does not operate..................................................................................................... 885 E-5 ECSS keeps operating...................................................................................................... 888 E-6 Defective boom kick-out function and cancellation......................................................................... 891 E-7 Defective bucket positioner function and cancellation..................................................................... 895 E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 899 E-9 Travel direction selection system does not function....................................................................... 903 E-10 Fan does not reverse..................................................................................................... 907 E-11 Fan keeps rotating in reverse............................................................................................ 911 E-12 Wiper does not operate................................................................................................... 913 E-13 Windshield washer does not operate....................................................................................... 917 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off......................................................... 921 E-15 Working lamp does not light up or go off................................................................................. 929 E-16 Turn signal lamp and hazard lamp do not light up or go off............................................................... 934 E-17 Brake lamp does not light or it keeps lighting up........................................................................ 941 E-18 Backup lamp does not light or it keeps lighting up....................................................................... 943 E-19 Backup alarm does not sound or it keeps sounding......................................................................... 946 E-20 Horn does not sound or it keeps sounding................................................................................. 949 E-21 Alarm buzzer does not sound or it keeps sounding......................................................................... 951 E-22 Air conditioner does not operate or stop................................................................................. 954 E-23 The KOMTRAX system does not work properly................................................................................ 957 500 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)................................................................... 960 METHOD OF USING TROUBLESHOOTING CHART......................................................................................... 962 FAILURE CODE AND CAUSE TABLE.................................................................................................. 965 H-1 THE MACHINE DOES NOT START................................................................................................ 967 H-2 THE TRAVEL SPEED IS SLOW.................................................................................................. 968 H-3 THE TRACTION FORCE IS WEAK................................................................................................ 969 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY............................................................ 970 H-5 THE GEAR IS NOT SHIFTED................................................................................................... 971 H-6 THE STEERING WHEEL DOES NOT TURN.......................................................................................... 972 H-7 THE STEERING WHEEL IS HEAVY............................................................................................... 973 H-8 STEERING WHEEL SHAKES OR JERKS............................................................................................ 974 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING..................................................................... 974 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL............................................................................ 975 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED.................................................................................. 976 H-12 THE LIFT ARM DOES NOT RISE OR LOWER...................................................................................... 977 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT................................................... 978 H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT........................................................ 979 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR).......................................... 979 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN............................................................................. 979 H-17 THE LIFT ARM WOBBLES DURING OPERATION.................................................................................... 979 H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ RAISE, ” THE LIFT ARM FALLS TEMPORARILY........................ 980 H-19 THE BUCKET DOES NOT TILT BACK............................................................................................ 981 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT........................................................ 982 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK.......................................................... 983 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.......................................................................... 983 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN............................................................................... 983 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH LOAD (THE WORK EQUIPMENT VALVE IS SET TO “ HOLD ” )............................... 983 H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ TILT, ” THE BUCKET FALLS TEMPORARILY........................... 984 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY............................................. 984 H-27 THE ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES................................................................ 985 H-28 FAN REVOLUTION IS ABNORMAL (FAN SOUND/VIBRATION IS ABNORMALLY LARGE OR ENGINE OVERHEATS)................................. 986 600 TROUBLESHOOTING OF ENGINE (S-MODE)............................................................................................ 988 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................ 989 S-1 STARTING PERFORMANCE IS POOR.............................................................................................. 993 S-2 ENGINE DOES NOT START..................................................................................................... 994 S-3 ENGINE DOES NOT PICK UP SMOOTHLY.......................................................................................... 997 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................ 998 S-5 ENGINE DOES NOT ROTATE SMOOTHLY........................................................................................... 999 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)......................................................................................1000 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................1001 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...................................................................1002 S-9 OIL BECOMES CONTAMINATED QUICKLY..........................................................................................1003 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................1004 S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)....................................................1005 S-12 OIL PRESSURE DROPS.......................................................................................................1006 S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)...............................................................................1007 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING).......................................................................1008 S-15 ABNORMAL NOISE IS MADE...................................................................................................1009 S-16 VIBRATION IS EXCESSIVE...................................................................................................1010 50 DISASSEMBLY AND ASSEMBLY........................................................................................................... 0 100 GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY...............................................................................1012 HOW TO READ THIS MANUAL.......................................................................................................1013 COATING MATERIALS LIST........................................................................................................1015 SPECIAL TOOL LIST.............................................................................................................1018 SKETCHES OF SPECIAL TOOLS.....................................................................................................1022 200 ENGINE AND COOLING SYSTEM.....................................................................................................1032 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY.........................................................................1033 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY............................................................................1036 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY............................................................................1043 REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY..............................................................................1056 REMOVAL AND INSTALLATION OF RADIATOR..........................................................................................1060 REMOVAL AND INSTALLATION OF AIR AFTERCOOLER...................................................................................1063 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.....................................................................1065 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...................................................................................1067 REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL ASSEMBLY....................................................................1074 REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL ASSEMBLY.....................................................................1077 REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY................................................................1080 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY................................................................................1083 310 POWER TRAIN, PART 1...........................................................................................................1086 DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY.................................................................................1087 REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY............................................................................1106 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY............................................................................1108 320 POWER TRAIN, PART 2...........................................................................................................1114 REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY...............................................................................1115 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY................................................................................1117 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY.............................................................................1120 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY.............................................................................1128 400 UNDERCARRIAGE AND FRAME.......................................................................................................1156 REMOVAL AND INSTALLATION OF CENTER HINGE PIN..................................................................................1157 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY............................................................................1166 500 HYDRAULIC SYSTEM..............................................................................................................1170 REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY.................................................................1171 DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY.................................................................................1175 REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY..............................................................................1202 REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY..............................................................................1204 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY................................................................................1206 REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.............................................................1222 REMOVAL AND INSTALLATION OF HYDRAULIC TANK....................................................................................1224 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.......................................................................1226 600 WORK EQUIPMENT................................................................................................................1232 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...........................................................................1233 700 CAB AND ITS ATTACHMENTS.......................................................................................................1242 REMOVAL AND INSTALLATION OF OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY...........................................................1243 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)................................................................1248 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT..............................................................................1256 800 ELECTRICAL SYSTEM.............................................................................................................1264 REMOVAL AND INSTALLATION OF MONITOR PANEL.....................................................................................1265 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY........................................................................1267 REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY...........................................................................1269 REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY.........................................................................1270 90 DIAGRAMS AND DRAWINGS.............................................................................................................. 0 100 HYDRAULIC DIAGRAMS AND DRAWINGS...............................................................................................1272 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................1274 200 ELECTRICAL DIAGRAMS AND DRAWINGS..............................................................................................1278 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................1280 CONNECTOR LIST AND STEREOGRAM.................................................................................................1290
KOMATSU WA200-6, WA200PZ-6 WHEEL LOADER SHOP MANUAL 70001 AND UP – PDF DOWNLOAD:
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Archer Crosby –
It was nice.