Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual SEN03862-10 PDF

Description

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual SEN03862-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual SEN03862-10 – PDF DOWNLOAD 

Language : English
Pages : 1310
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual SEN03862-10 – PDF DOWNLOAD 

Cover 1
00 INDEX AND FOREWORD 3
100 INDEX 3
Composition of shop manual 4
Table of contents 6
200 FOREWORD AND GENERAL INFORMATION 17
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling of electric equipment and hydraulic component 27
Handling of connectors newly used for engines 36
How to read electric wire code 39
Precautions when carrying out operation 42
Method of disassembling and connecting push-pull type coupler 45
Standard tightening torque table 48
Conversion table 52
01 SPECIFICATION 59
100 SPECIFICATION AND TECHNICAL DATA 59
SPECIFICATION DIMENSION DRAWING 61
SPECIFICATIONS 62
WEIGHT TABLE 66
TABLE OF FUEL, COOLANT AND LUBRICANTS 68
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 71
100 ENGINE AND COOLING SYSTEM 71
ENGINE MOUNT AND TRANSFER MOUNT 72
DAMPER 73
COOLING SYSTEM 74
COOLING SYSTEM HYDRAULIC PIPING DIAGRAM 75
COOLING FAN MOTOR 77
200 POWER TRAIN 87
POWER TRAIN 89
POWER TRAIN SYSTEM DIAGRAM 90
DRIVE SHAFT 92
HST HYDRAULIC PIPING DIAGRAM 93
HST PUMP 94
HST MOTOR 102
TRANSFER 108
CLUTCH SOLENOID VALVE 119
AXLE 120
DIFFERENTIAL 122
TORQUE PROPORTIONING 127
LIMITED SLIP DIFFERENTIAL 130
FINAL DRIVE 134
300 STEERING SYSTEM 139
Steering piping diagram 141
Steering column 142
Priority valve 143
Orbit-roll valve 146
2-way restrictor valve 154
Cushion valve 155
Steering cylinder 156
Emergency steering piping diagram 158
Emergency steering valve 159
Steering relief valve 162
400 BRAKE SYSTEM 165
BRAKE PIPING DIAGRA 167
CHARGE VALVE 168
BRAKE VALVE 172
INCHING VALVE 176
ACCUMULATOR (FOR BRAKE) 177
SLACK ADJUSTER 178
BRAKE 180
PARKING BRAKE CONTROL 185
PARKING BRAKE 186
500 UNDERCARRIAGE AND FRAME 189
Axle mount and center hinge pin 190
Tires 195
600 HYDRAULIC SYSTEM 197
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 198
WORK EQUIPMENT CONTROL LEVER LINKAGE 202
HYDRAULIC TANK 206
4-GEAR PUMP 208
WORK EQUIPMENT CONTROL VALVE 211
PPC VALVE 235
LOCK VALVE 250
ACCUMULATOR (FOR PPC CIRCUIT) 251
BYPASS VALVE 252
QUICK COUPLER SOLENOID VALVE 255
ECSS VALVE 256
ACCUMULATOR (FOR ECSS) 258
700 WORK EQUIPMENT 261
Work equipment linkage 262
Bucket 266
Bucket positioner and boom kick-out 270
Work equipment cylinder 282
800 CAB AND ITS ATTACHMENTS 287
CAB 289
AIR CONDITIONER 290
910 ELECTRICAL SYSTEM, PART 1 303
MACHINE MONITOR SYSTEM 304
MACHINE MONITOR 308
920 ELECTRICAL SYSTEM, PART 2 331
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM) 332
HST CONTROLLER 348
ECSS SYSTEM 350
KOMTRAX SYSTEM 352
ENGINE STARTING CIRCUIT 354
ENGINE STOPPING CIRCUIT 356
PREHEATING CIRCUIT 357
ENGINE OUTPUT DERATING FUNCTION 358
AUTOMATIC WARM-UP FUNCTION 358
PARKING BRAKE CIRCUIT 359
COUPLER PLUNGER CONTROL SYSTEM 362
MULTI-FUNCTION KNOB 363
MAX TRACTION SWITCH 364
SENSOR 365
20 STANDARD VALUE TABLE 373
100 STANDARD SERVICE VALUE TABLE 373
STANDARD SERVICE VALUE TABLE FOR ENGINE 374
STANDARD SERVICE VALUE TABLE FOR CHASSIS 375
30 TESTING AND ADJUSTING 383
110 TESTING AND ADJUSTING, PART 1 383
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 384
Sketches of special tools 389
Measuring engine speed 390
Measuring exhaust gas color 392
ADJUSTING VALVE CLEARANCE 393
MEASURING COMPRESSION PRESSURE 395
MEASURING BLOW-BY PRESSURE 398
TESTING ENGINE OIL PRESSURE 399
MEASURING INTAKE AIR (BOOST) PRESSURE 400
HANDLING FUEL SYSTEM EQUIPMENT 402
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM 402
MEASURING FUEL PRESSURE 403
MEASURING FUEL RETURN RATE AND LEAKAGE 405
BLEEDING AIR FROM FUEL CIRCUIT 409
Checking leakage in fuel system 410
Handling cylinder cut-out mode operation 411
Handling no-injection cranking operation 411
HANDLING CONTROLLER VOLTAGE CIRCUIT 412
CHECK OF MUFFLER AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 412
CHECK OF MUFFLER FUNCTION 413
CHECK OF INSTALLED CONDITION OF CYLINDER HEAD AND MANIFOLDS 413
CHECK OF ENGINE PIPING FOR DAMAGE AND LOOSENESS 414
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 414
REPLACING ALTERNATOR BELT 415
120 TESTING AND ADJUSTING, PART 2 417
CHECKING OPERATING FORCE OF ACCELERATOR PEDAL 419
CHECKING DIRECTIONAL LEVER 420
TESTING AND ADJUSTING HST OIL PRESSURE 421
TESTING CLUTCH CONTROL PRESSURE 426
TESTING AND ADJUSTING STEERING WHEEL 427
TESTING AND ADJUSTING STEERING OIL PRESSURE 429
BLEEDING AIR FROM STEERING CIRCUIT 431
TESTING HYDRAULIC FAN 432
MEASURING BRAKE PEDAL 434
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 435
MEASURING BRAKE PERFORMANCE 436
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 437
TESTING WHEEL BRAKE OIL PRESSURE 439
TESTING WEAR OF BRAKE DISC 442
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT 443
RELEASING RESIDUAL PRESSURE IN BRAKE ACCUMULATOR CIRCUIT 444
TESTING PARKING BRAKE PERFORMANCE 445
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE 446
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER 447
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 448
TESTING WORK EQUIPMENT PPC OIL PRESSURE 449
BLEEDING AIR FROM HYDRAULIC CIRCUIT 451
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 452
TESTING AND ADJUSTING BUCKET POSITIONER 453
TESTING AND ADJUSTING OF BOOM KICK-OUT SWITCH 455
CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP 456
PROCEDURE FOR TESTING DIODES 457
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 459
STARTING KOMTRAX TERMINAL OPERATIONS 463
INDICATOR LAMPS OF KOMTRAX TERMINAL 467
130 TESTING AND ADJUSTING, PART 3 471
ADJUSTING MACHINE MONITOR 472
ADJUSTING REPLACED, REASSEMBLED OR ADDED SENSOR, CONTROLLER, ETC WITH MACHINE MONITOR 473
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS) 475
PM CLINIC INSPECTION CHART 529
40 TROUBLESHOOTING 533
100 FAILURE CODE TABLE AND FUSE LOCATIONS 533
FAILURE CODES TABLE 534
FUSE LOCATIONS 540
200 General information on troubleshooting 545
Points to remember when troubleshooting 546
Sequence of events in troubleshooting 547
Testing before troubleshooting 548
Classification and procedures of troubleshooting 549
Information contained in troubleshooting table 552
Connection table for connector pin numbers 554
T- branch box and T- branch adapter table 590
310 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1 595
FAILURE CODE [2G40GZ] BRAKE: OIL PRESSURE REDUCTION 596
FAILURE CODE [6091NX] HST FILTER: CLOGGING 598
FAILURE CODE [989FN1] TRAVEL SPEED: OVERRUN ALARM 599
FAILURE CODE [AB00L6] ALTERNATOR R SYSTEM: HOT SHORT 600
FAILURE CODE [AB00MA] ALTERNATOR R SYSTEM: GROUND FAULT/DISCONNECTION CHARGE/LOW CHARGE VOLTAGE 602
FAILURE CODE [B@BAZG] ENGINE: OIL PRESSURE REDUCTION 604
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT 605
FAILURE CODE [B@BCZK] ENGINE: LOW COOLANT LEVEL 606
FAILURE CODE [B@C6NS] FRONT BRAKE: HIGH OIL TEMPERATURE 608
FAILURE CODE [B@CRNS] HST: HIGH OIL TEMPERATURE 609
320 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2 611
FAILURE CODE [CA111] ABNORMALITY IN ENGINE CONTROLLER 613
FAILURE CODE [CA115] ENGINE NE OR BKUP SPEED SENSOR ERROR 614
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR HIGH ERROR 616
FAILURE CODE [CA123] CHARGE PRESSURE SENSOR LOW ERROR 618
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR 620
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR 622
FAILURE CODE [CA144] COOLANT SENSOR HIGH ERROR 624
FAILURE CODE [CA145] COOLANT SENSOR LOW ERROR 626
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR HIGH ERROR 628
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR LOW ERROR 630
FAILURE CODE [CA155] DERATING OF SPEED BY ABNORMALLY HIGH CHARGE TEMPERATURE 632
FAILURE CODE [CA187] SENSOR POWER SUPPLY 2 LOW ERROR 634
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR HIGH ERROR 636
FAILURE CODE [CA222] ATMOSPHERIC SENSOR LOW ERROR 638
FAILURE CODE [CA227] SENSOR POWER SUPPLY 2 HIGH ERROR 640
FAILURE CODE [CA234] ENGINE OVERSPEED 641
FAILURE CODE [CA238] NE SPEED SENSOR POWER SUPPLY ERROR 642
FAILURE CODE [CA271] IMV (IMA) SHORT CIRCUIT 643
FAILURE CODE [CA272] IMV (IMA) DISCONNECTION 644
FAILURE CODE [CA322] INJECTOR #1 OPEN/SHORT ERROR 646
FAILURE CODE [CA324] INJECTOR #3 OPEN/SHORT ERROR 648
FAILURE CODE [CA331] INJECTOR #2 OPEN/SHORT ERROR 650
FAILURE CODE [CA332] INJECTOR #4 OPEN/SHORT ERROR 652
FAILURE CODE [CA342] CALIBRATION CODE INCONSISTENCY 654
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR 656
FAILURE CODE [CA352] SENSOR POWER SUPPLY 1 LOW ERROR 658
FAILURE CODE [CA386] SENSOR POWER SUPPLY 1 HIGH ERROR 660
330 Troubleshooting by failure code (Display of code), Part 3 663
Failure code [CA428] Abnormally high level in water sensor 666
Failure code [CA429] Abnormally low level in water sensor 668
Failure code [CA431] Idle validation switch error 670
Failure code [CA432] Idle validation action error 674
Failure code [CA435] Engine oil pressure switch error 678
Failure code [CA441] Battery voltage low error 679
Failure code [CA442] Battery voltage high error 682
Failure code [CA449] Common rail pressure high error 2 684
Failure code [CA451] Common rail pressure sensor high error 686
Failure code [CA452] Common rail pressure sensor low error 688
Failure code [CA488] Derating of torque by abnormally high charge temperature 690
Failure code [CA553] Common rail pressure high error 1 691
Failure code [CA559] Supply pump pressure very low error 692
Failure code [CA689] Engine Ne speed sensor error 694
Failure code [CA731] Engine Bkup speed sensor phase error 696
Failure code [CA757] All continuous data lost error 697
Failure code [CA778] Engine Bkup speed sensor error 700
Failure code [CA1633] KOMNET datalink timeout error 702
Failure code [CA2185] Throttle sensor supply voltage high error 704
Failure code [CA2186] Throttle sensor power supply low error 706
Failure code [CA2249] Supply pump pressure very low error 2 708
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 710
Failure code [CA2555] Intake heater relay disconnection error 712
Failure code [CA2556] Intake heater relay short circuit error 714
340 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4 717
FAILURE CODE [D160KY] BACKUP ALARM/LAMP RELAY 1 CIRCUIT: HOT SHORT 718
FAILURE CODE [D192KY] ECSS SOLENOID RELAY: HOT SHORT 720
FAILURE CODE [D1B0KA] HST SAFETY RELAY: DISCONNECTION 722
FAILURE CODE [D1B0KB] HST SAFETY RELAY: GROUND FAULT 724
FAILURE CODE [D1B0KY] HST SAFETY RELAY: HOT SHORT 726
FAILURE CODE [D5ZHL6] IGN C SYSTEM: GROUND FAULT/DISCONNECTION 728
FAILURE CODE [DAF3KK] UNSW POWER SUPPLY: GROUND FAULT/DISCONNECTION 730
FAILURE CODE [DAFRKR] MACHINE MONITOR CAN-NET SIGNAL: DISCONNECTION 732
FAILURE CODE [DAJ0KK] HST CONTROLLER POWER SUPPLY: LOW VOLTAGE 736
FAILURE CODE [DAJ0KT] HST CONTROLLER MEMORY (EEPROM): ABNORMALITY 738
FAILURE CODE [DAJ1L4] HST CONTROLLER MAIN POWER LINE: DISCONNECTION/GROUND FAULT 740
FAILURE CODE [DAJ1L6] HST CONTROLLER MAIN POWER LINE: HOT SHORT 742
FAILURE CODE [DAJ2KK] CONTROLLER SOLENOID POWER SUPPLY: LOW VOLTAGE 744
FAILURE CODE [DAJ2L3] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: HOT SHORT IN WIRING HARNESS 746
FAILURE CODE [DAJ2L4] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: DISCONNECTION/GROUND FAULT 748
FAILURE CODE [DAJ5KX] SENSOR 5V POWER SUPPLY: OUT OF OUTPUT RANGE 750
FAILURE CODE [DAJ9KQ] HST CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS 752
FAILURE CODE [DAJRKR] HST CONTROLLER CAN-NET SIGNAL: DISCONNECTION 753
FAILURE CODE [DAJRMA] HST CONTROLLER: DISAGREEMENT IN OPTION SELECTION 759
350 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5 761
FAILURE CODE [DB2RKR] ENGINE CONTROLLER CAN-NET: DISCONNECTION IN SIGNAL LINE 762
FAILURE CODE [DD1NL4] FAN AUTOMATIC REVERSE SWITCH SIGNAL: ABNORMALITY 768
FAILURE CODE [DD1NLD] FAN REVERSE SWITCH SIGNAL: ABNORMALITY 770
FAILURE CODE [DDB6KA] PARKING BRAKE SWITCH A: DISCONNECTION/HOT SHORT 772
FAILURE CODE [DDB6KB] PARKING BRAKE SWITCH B: GROUND FAULT 774
FAILURE CODE [DDB6KZ] PARKING BRAKE SWITCH (BOTTOM SWITCH) OR PARKING BRAKE REMINDER SWITCH (INTERMEDIATE SWITCH): TROUBLE 776
FAILURE CODE [DDB6L0] PARKING BRAKE SWITCH A: GROUND FAULT 778
FAILURE CODE [DDB6L4] PARKING BRAKE SWITCH B: DISCONNECTION/HOT SHORT 780
FAILURE CODE [DDD7KX] TRAVEL SPEED CONTROL DIAL SIGNAL: DISCONNECTION/GROUND FAULT 782
FAILURE CODE [DDD7KY] TRAVEL SPEED CONTROL DIAL SIGNAL: HOT SHORT 784
FAILURE CODE [DDE5MA] EMERGENCY STEERING OPERATION SWITCH: DISCONNECTION 786
FAILURE CODE [DDK3KA] DIRECTIONAL SELECTOR SWITCH: DISCONNECTION/HOT SHORT 788
FAILURE CODE [DDK3KB] DIRECTIONAL SELECTOR SWITCH: GROUND FAULT 790
FAILURE CODE [DDK6KA] FNR LEVER: DISCONNECTION/GROUND FAULT 792
FAILURE CODE [DDK6KY] FNR LEVER: HOT SHORT 796
FAILURE CODE [DDS5L6] STEERING: LOW OIL PRESSURE (OPERATION OF EMERGENCY STEERING) 798
360 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6 801
FAILURE CODE [DF10KA] TRAVEL SPEED RANGE SELECTOR SWITCH: DISCONNECTION/GROUND FAULT 802
FAILURE CODE [DF10KB] TRAVEL SPEED RANGE SELECTOR SWITCH: HOT SHORT 806
FAILURE CODE [DGH1KX] HST OIL TEMPERATURE SENSOR: GROUND FAULT 808
FAILURE CODE [DGR2KB] BRAKE OIL TEMPERATURE SENSOR: GROUND FAULT 809
FAILURE CODE [DGR2KZ] BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION/HOT SHORT 810
FAILURE CODE [DHH1KX] HST OIL PRESSURE SENSOR: DISCONNECTION/GROUND FAULT 812
FAILURE CODE [DHH1KY] HST OIL PRESSURE SENSOR: HOT SHORT 814
FAILURE CODE [DHTCL6] HST FILTER CLOGGING SENSOR: FUNCTIONAL DEFECT 816
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION/HOT SHORT 818
FAILURE CODE [DLT3KX] TRAVEL SPEED SENSOR B: ABNORMALITY 820
FAILURE CODE [DLT4KX] TRAVEL SPEED SENSOR A: ABNORMALITY 824
FAILURE CODE [DLT4LC] TRAVEL SPEED SENSOR A & B: ABNORMALITY 826
FAILURE CODE [DV00KY] ALARM BUZZER: HOT SHORT 828
FAILURE CODE [DW26KA] MOTOR 2 SOLENOID: DISCONNECTION/GROUND FAULT 830
FAILURE CODE [DW26KY] MOTOR 2 SOLENOID: HOT SHORT 832
FAILURE CODE [DW7BKY] FAN REVERSE SOLENOID CIRCUIT: HOT SHORT 834
FAILURE CODE [DW7BKZ] FAN REVERSE SOLENOID CIRCUIT: DISCONNECTION/GROUND FAULT 836
370 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 7 839
FAILURE CODE [DX16KA] FAN EPC SOLENOID: DISCONNECTION 840
FAILURE CODE [DX16KB] FAN EPC SOLENOID: GROUND FAULT 841
FAILURE CODE [DX16KY] FAN EPC SOLENOID: HOT SHORT 842
FAILURE CODE [DX19KA] MOTOR 1 SOLENOID: DISCONNECTION 844
FAILURE CODE [DX19KB] MOTOR 1 SOLENOID: GROUND FAULT 846
FAILURE CODE [DX19KY] MOTOR 1 SOLENOID: HOT SHORT 848
FAILURE CODE [DX20KA] CLUTCH EPC SOLENOID: DISCONNECTION 850
FAILURE CODE [DX20KB] CLUTCH EPC SOLENOID: GROUND FAULT 852
FAILURE CODE [DX20KY] CLUTCH EPC SOLENOID: HOT SHORT 854
FAILURE CODE [DXH7KB] REVERSE SOLENOID: GROUND FAULT 856
FAILURE CODE [DXH7KZ] REVERSE SOLENOID: DISCONNECTION/HOT SHORT 858
FAILURE CODE [DXH8KB] FORWARD SOLENOID: GROUND FAULT 860
FAILURE CODE [DXH8KZ] FORWARD SOLENOID: DISCONNECTION/HOT SHORT 862
FAILURE CODE [J141N1] STEERING PUMP: OVERRUN ALARM 864
FAILURE CODE [M100N1] HST PUMP: OVERRUN ALARM 864
FAILURE CODE [M400N1] MOTOR 1: OVERRUN ALARM 865
400 Troubleshooting of electrical system(E-mode) 867
E-1 Engine does not start 869
E-2 Preheater does not operate normally 876
E-3 Travel speed is low or high 880
E-4 ECSS does not operate 886
E-5 ECSS keeps operating 889
E-6 Defective boom kick-out function and cancellation 892
E-7 Defective bucket positioner function and cancellation 896
E-8 Defective lift arm FLOATING holding function and cancellation 900
E-9 Travel direction selection system does not function 904
E-10 Fan does not reverse 908
E-11 Fan keeps rotating in reverse 912
E-12 Wiper does not operate 914
E-13 Windshield washer does not operate 918
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off 922
E-15 Working lamp does not light up or go off 930
E-16 Turn signal lamp and hazard lamp do not light up or go off 935
E-17 Brake lamp does not light or it keeps lighting up 942
E-18 Backup lamp does not light or it keeps lighting up 944
E-19 Backup alarm does not sound or it keeps sounding 947
E-20 Horn does not sound or it keeps sounding 950
E-21 Alarm buzzer does not sound or it keeps sounding 952
E-22 Air conditioner does not operate or stop 955
E-23 The KOMTRAX system does not work properly 958
500 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 961
METHOD OF USING TROUBLESHOOTING CHART 963
FAILURE CODE AND CAUSE TABLE 966
H-1 THE MACHINE DOES NOT START 968
H-2 THE TRAVEL SPEED IS SLOW 969
H-3 THE TRACTION FORCE IS WEAK 970
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY 971
H-5 THE GEAR IS NOT SHIFTED 972
H-6 THE STEERING WHEEL DOES NOT TURN 973
H-7 THE STEERING WHEEL IS HEAVY 974
H-8 STEERING WHEEL SHAKES OR JERKS 975
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 975
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL 976
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED 977
H-12 THE LIFT ARM DOES NOT RISE OR LOWER 978
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 979
H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT 980
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR) 980
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN 980
H-17 THE LIFT ARM WOBBLES DURING OPERATION 980
H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ RAISE, ” THE LIFT ARM FALLS TEMPORARILY 981
H-19 THE BUCKET DOES NOT TILT BACK 982
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT 983
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK 984
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET 984
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN 984
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH LOAD (THE WORK EQUIPMENT VALVE IS SET TO “ HOLD ” ) 984
H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ TILT, ” THE BUCKET FALLS TEMPORARILY 985
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 985
H-27 THE ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES 986
H-28 FAN REVOLUTION IS ABNORMAL (FAN SOUND/VIBRATION IS ABNORMALLY LARGE OR ENGINE OVERHEATS) 987
600 TROUBLESHOOTING OF ENGINE (S-MODE) 989
METHOD OF USING TROUBLESHOOTING CHARTS 990
S-1 STARTING PERFORMANCE IS POOR 994
S-2 ENGINE DOES NOT START 995
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 998
S-4 ENGINE STOPS DURING OPERATIONS 999
S-5 ENGINE DOES NOT ROTATE SMOOTHLY 1000
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 1001
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 1002
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 1003
S-9 OIL BECOMES CONTAMINATED QUICKLY 1004
S-10 FUEL CONSUMPTION IS EXCESSIVE 1005
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1006
S-12 OIL PRESSURE DROPS 1007
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL) 1008
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1009
S-15 ABNORMAL NOISE IS MADE 1010
S-16 VIBRATION IS EXCESSIVE 1011
50 DISASSEMBLY AND ASSEMBLY 1013
100 GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY 1013
How to read this manual 1014
Coating materials list 1016
Special tool list 1019
Sketches of special tools 1023
200 ENGINE AND COOLING SYSTEM 1035
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY 1036
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY 1039
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 1046
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY 1059
REMOVAL AND INSTALLATION OF RADIATOR 1063
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER 1066
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 1068
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1070
REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL ASSEMBLY 1077
REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL ASSEMBLY 1080
REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY 1083
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY 1086
310 POWER TRAIN, PART 1 1089
Disassembly and assembly of transfer assembly 1090
Removal and installation of parking brake assembly 1110
Disassembly and assembly of parking brake assembly 1112
320 POWER TRAIN, PART 2 1119
Removal and installation of front axle assembly 1120
Removal and installation of rear axle assembly 1122
Disassembly and assembly of axle housing assembly 1125
Disassembly and assembly of differential assembly 1133
400 UNDERCARRIAGE AND FRAME 1161
Removal and installation of center hinge pin 1162
Removal and installation of counterweight assembly 1171
500 HYDRAULIC SYSTEM 1175
Removal and installation of HST pump and 4-gear pump assembly 1176
Disassembly and assembly of HST pump assembly 1180
Removal and installation of HST motor 1 assembly 1207
Removal and installation of HST motor 2 assembly 1209
Disassembly and assembly of HST motor assembly 1211
Removal and installation of work equipment control valve assembly 1227
Removal and installation of hydraulic tank 1229
Disassembly and assembly of hydraulic cylinder assembly 1231
600 WORK EQUIPMENT 1237
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1238
700 CAB AND ITS ATTACHMENTS 1247
REMOVAL AND INSTALLATION OF OPERATOR’S CAB AND FLOOR FRAME ASSEMBLY 1248
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) 1253
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT 1261
800 ELECTRICAL SYSTEM 1269
REMOVAL AND INSTALLATION OF MONITOR PANEL 1270
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY 1272
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY 1274
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY 1275
90 DIAGRAMS AND DRAWINGS 1277
100 HYDRAULIC DIAGRAMS AND DRAWINGS 1277
HYDRAULIC CIRCUIT DIAGRAM 1279
200 ELECTRICAL DIAGRAMS AND DRAWINGS 1285
ELECTRICAL CIRCUIT DIAGRAM 1287
CONNECTOR LIST AND STEREOGRAM 1307

DESCRIPTION:

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual SEN03862-10 – PDF DOWNLOAD

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. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and 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. 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.
30. 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.
40. 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.
50. 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. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

S.V 29/12/24