Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual VEBM600101 PDF

Description

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual VEBM600101 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual VEBM600101 – PDF DOWNLOAD 

Language : English
Pages : 1237
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual VEBM600101 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
WA200-6                    75001 and up
WA200PZ-6               70136 and up
H00051 and up

00 Index and foreword 3
100 Index 3
Composition of shop manual 4
Table of contents 6
200 Foreword and general information 15
Safety notice 16
How to read the shop manual 21
Explanation of terms for maintenance standard 23
Handling of electric equipment and hydraulic component 25
Handling of connectors newly used for engines 34
How to read electric wire code 37
Precautions when carrying out operation 40
Method of disassembling and connecting push-pull type coupler 43
Standard tightening torque table 46
Conversion table 50
01 Specification 55
100 Specification and technical data 55
Specification dimension drawing 57
Specifications 58
Weight table 62
Table of fuel, coolant and lubricants 64
10 Structure, function and maintenance standard 65
100 Engine and cooling system 65
Engine mount and transfer mount 66
Damper 67
Cooling system 68
Cooling system hydraulic piping diagram 69
Cooling fan motor 71
200 Power train 79
Power train 81
Power train system diagram 82
Drive shaft 84
HST hydraulic piping diagram 85
HST pump 86
HST motor 94
Transfer 100
Clutch solenoid valve 111
Axle 112
Differential 114
Torque proportioning differential 119
Limited slip differential 122
Final drive 126
300 Steering system 131
Steering piping diagram 133
Steering column 134
Priority valve 135
Orbit-roll valve 138
2-way restrictor valve 146
Cushion valve 147
Steering cylinder 148
Emergency steering piping diagram 150
Emergency steering valve 151
Steering relief valve 154
400 Brake system 155
Brake piping diagram 157
Charge valve 158
Brake valve 162
Inching valve 166
Accumulator (for brake) 167
Slack adjuster 168
Brake 170
Parking brake control 175
Parking brake 176
500 Undercarriage and frame 177
Axle mount and center hinge pin 178
Tires 183
600 Hydraulic system 185
Work equipment hydraulic piping diagram 186
Work equipment control lever linkage 190
Hydraulic tank 194
4-gear pump 196
Work equipment control valve 199
PPC valve 223
Lock valve 238
Accumulator (for PPC circuit) 239
Bypass valve 240
Quick coupler solenoid valve 243
ECSS valve 244
Accumulator (for ECSS) 246
700 Work equipment 247
Work equipment linkage 248
Bucket 252
Bucket positioner and boom kick-out 256
Work equipment cylinder 269
800 Cab and its attachments 273
Cab 275
Air conditioner 276
910 Electrical system, Part 1 289
Machine monitor system 290
Machine monitor 294
920 Electrical system, Part 2 315
Electrical system (HST controller system) 316
HST controller 332
ECSS system 334
KOMTRAX system 336
Engine starting circuit 338
Engine stopping circuit 340
Preheating circuit 341
Engine output derating function 342
Automatic warm-up function 342
Parking brake circuit 343
Coupler plunger control system 346
Multi-function knob 347
Max traction switch 348
Sensor 349
20 Standard value table 355
100 Standard service value table 355
Standard service value table for engine 356
Standard service value table for chassis 357
30 Testing and adjusting 363
110 Testing and adjusting, Part 1 363
Tools for testing, adjusting, and troubleshooting 364
Measuring engine speed 369
Measuring exhaust gas color 371
Adjusting valve clearance 373
Measuring compression pressure 375
Measuring blow-by pressure 378
Testing engine oil pressure 379
Measuring intake air (boost) pressure 380
Handling fuel system equipment 382
Releasing residual pressure in fuel system 382
Measuring fuel pressure 383
Measuring fuel return rate and leakage 385
Bleeding air from fuel circuit 389
Testing leakage in fuel system 390
Handling reduced cylinder mode operation 391
Handling no-injection cranking operation 391
Handling controller voltage circuit 392
Check of muffler and muffler stack for looseness and damage 392
Check of muffler function 393
Check of installed condition of cylinder head and manifolds 393
Check of engine piping for damage and looseness 394
Testing and adjusting air conditioner compressor belt tension 394
Replacing alternator belt 395
120 Testing and adjusting, Part 2 397
Checking operating force of accelerator pedal 399
Checking directional lever 400
Testing and adjusting HST oil pressure 401
Testing clutch control pressure 405
Testing and adjusting steering wheel 406
Testing and adjusting steering oil pressure 408
Bleeding air from steering circuit 410
Testing hydraulic fan 411
Measuring brake pedal 413
Testing and adjusting brake pedal linkage 414
Measuring brake performance 415
Testing and adjusting accumulator charge pressure 416
Testing wheel brake oil pressure 418
Testing wear of brake disc 421
Bleeding air from wheel brake circuit 422
Releasing residual pressure in brake accumulator circuit 423
Testing parking brake performance 424
Testing and adjusting parking brake control cable 425
Measuring and adjusting work equipment control lever 426
Testing and adjusting work equipment hydraulic pressure 427
Testing work equipment PPC oil pressure 428
Bleeding air from hydraulic circuit 430
Releasing remaining pressure in hydraulic circuit 431
Testing and adjusting bucket positioner 432
Testing and adjusting boom kick- out switch 434
Checking proximity switch operation pilot lamp 435
Procedure for testing diodes 436
Preparation work for troubleshooting for electric system 438
Starting KOMTRAX terminal operations 442
Indicator lamps of KOMTRAX terminal 446
130 Testing and adjusting, Part 3 449
Adjusting machine monitor 450
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 451
Special functions of machine monitor (EMMS) 453
Pm clinic inspection chart 507
40 Troubleshooting 509
100 Failure code table and fuse locations 509
Failure codes table 510
Fuse locations 516
200 General information on troubleshooting 519
Points to remember when troubleshooting 520
Sequence of events in troubleshooting 521
Testing before troubleshooting 522
Classification and procedures of troubleshooting 523
Information contained in troubleshooting table 526
Connection table for connector pin numbers 528
T- branch box and T- branch adapter table 563
310 Troubleshooting by failure code (Display of code), Part 1 567
Failure code [2G40GZ] Brake: Oil pressure reduction 568
Failure code [6091NX] HST filter: Clogging 570
Failure code [989FN1] Travel speed: Overrun alarm 571
Failure code [AB00L6] Alternator R system: Hot short 572
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage 574
Failure code [B@BAZG] Engine: Oil pressure reduction 576
Failure code [B@BCNS] Engine: Overheat 577
Failure code [B@BCZK] Engine: Low coolant level 578
Failure code [B@C6NS] Front brake: High oil temperature 580
Failure code [B@CRNS] HST: High oil temperature 581
320 Troubleshooting by failure code (Display of code), Part 2 583
Failure code [CA111] Abnormality in engine controller 585
Failure code [CA115] Engine Ne or Bkup speed sensor error 586
Failure code [CA122] Charge pressure sensor high error 588
Failure code [CA123] Charge pressure sensor low error 590
Failure code [CA131] Throttle sensor high error 592
Failure code [CA132] Throttle sensor low error 594
Failure code [CA144] Coolant sensor high error 596
Failure code [CA145] Coolant sensor low error 598
Failure code [CA153] Charge temperature sensor high error 600
Failure code [CA154] Charge temperature sensor low error 602
Failure code [CA155] Derating of speed by abnormally high charge temperature 604
Failure code [CA187] Sensor power supply 2 low error 606
Failure code [CA221] Atmospheric pressure sensor high error 608
Failure code [CA222] Atmospheric sensor low error 610
Failure code [CA227] Sensor power supply 2 high error 612
Failure code [CA234] Engine overspeed 613
Failure code [CA238] Ne speed sensor power supply error 614
Failure code [CA271] IMV (IMA) Short circuit 615
Failure code [CA272] IMV (IMA) Disconnection 616
Failure code [CA322] Injector #1 open/short error 618
Failure code [CA324] Injector #3 open/short error 620
Failure code [CA331] Injector #2 open/short error 622
Failure code [CA332] Injector #4 open/short error 624
Failure code [CA342] Calibration code inconsistency 626
Failure code [CA351] Injectors drive circuit error 628
Failure code [CA352] Sensor power supply 1 low error 630
Failure code [CA386] Sensor power supply 1 high error 632
330 Troubleshooting by failure code (Display of code), Part 3 633
Failure code [CA428] Abnormally high level in water sensor 636
Failure code [CA429] Abnormally low level in water sensor 638
Failure code [CA431] Idle validation switch error 640
Failure code [CA432] Idle validation action error 644
Failure code [CA435] Engine oil pressure switch error 648
Failure code [CA441] Battery voltage low error 649
Failure code [CA442] Battery voltage high error 652
Failure code [CA449] Common rail pressure high error 2 654
Failure code [CA451] Common rail pressure sensor high error 656
Failure code [CA452] Common rail pressure sensor low error 658
Failure code [CA488] Derating of torque by abnormally high charge temperature 660
Failure code [CA553] Common rail pressure high error 1 661
Failure code [CA559] Supply pump pressure very low error 662
Failure code [CA689] Engine Ne speed sensor error 664
Failure code [CA731] Engine Bkup speed sensor phase error 666
Failure code [CA757] All continuous data lost error 667
Failure code [CA778] Engine Bkup speed sensor error 670
Failure code [CA1633] KOMNET datalink timeout error 672
Failure code [CA2185] Throttle sensor supply voltage high error 676
Failure code [CA2186] Throttle sensor power supply low error 678
Failure code [CA2249] Supply pump pressure very low error 2 680
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 682
Failure code [CA2555] Intake heater relay disconnection error 684
Failure code [CA2556] Intake heater relay short circuit error 686
340 Troubleshooting by failure code (Display of code), Part 4 689
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short 690
Failure code [D192KY] ECSS solenoid relay: Hot short 692
Failure code [D1B0KA] HST safety relay: Disconnection 694
Failure code [D1B0KB] HST safety relay: Ground fault 696
Failure code [D1B0KY] HST safety relay: Hot short 698
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection 700
Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection 702
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection 704
Failure code [DAJ0KK] HST controller power supply: Low voltage 708
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality 710
Failure code [DAJ1L4] HST controller main power line: Disconnection/ Ground fault 712
Failure code [DAJ1L6] HST controller main power line: Hot short 714
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage 716
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness 718
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault 720
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range 722
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals 724
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection 725
Failure code [DAJRMA] HST controller: Disagreement in option selection 731
350 Troubleshooting by failure code (Display of code), Part 5 733
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line 734
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality 740
Failure code [DD1NLD] Fan reverse switch signal: Abnormality 742
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short 744
Failure code [DDB6KB] Parking brake switch B: Ground fault 746
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble 748
Failure code [DDB6L0] Parking brake switch A: Ground fault 750
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short 752
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/ Ground fault 754
Failure code [DDD7KY] Travel speed control dial signal: Hot short 756
Failure code [DDE5MA] Emergency steering operation switch: Disconnection 758
Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short 760
Failure code [DDK3KB] Directional selector switch: Ground fault 762
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault 764
Failure code [DDK6KY] FNR lever: Hot short 768
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) 770
360 Troubleshooting by failure code (Display of code), Part 6 773
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault 774
Failure code [DF10KB] Travel speed range selector switch: Hot short 778
Failure code [DGH1KX] HST oil temperature sensor: Ground fault 780
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault 781
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short 782
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault 784
Failure code [DHH1KY] HST oil pressure sensor: Hot short 786
Failure code [DHTCL6] HST filter clogging sensor: Functional defect 788
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short 790
Failure code [DLT3KX] Travel speed sensor B: Abnormality 792
Failure code [DLT4KX] Travel speed sensor A: Abnormality 796
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality 798
Failure code [DV00KY] Alarm buzzer: Hot short 800
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault 802
Failure code [DW26KY] Motor 2 solenoid: Hot short 804
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short 806
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault 808
370 Troubleshooting by failure code (Display of code), Part 7 811
Failure code [DX16KA] Fan EPC solenoid: Disconnection 812
Failure code [DX16KB] Fan EPC solenoid: Ground fault 813
Failure code [DX16KY] Fan EPC solenoid: Hot short 814
Failure code [DX19KA] Motor 1 solenoid: Disconnection 816
Failure code [DX19KB] Motor 1 solenoid: Ground fault 818
Failure code [DX19KY] Motor 1 solenoid: Hot short 820
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 822
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 824
Failure code [DX20KY] Clutch EPC solenoid: Hot short 826
Failure code [DXH7KB] Reverse solenoid: Ground fault 828
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 830
Failure code [DXH8KB] Forward solenoid: Ground fault 832
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 834
Failure code [J141N1] Steering pump: Overrun alarm 836
Failure code [M100N1] HST pump: Overrun alarm 836
Failure code [M400N1] Motor 1: Overrun alarm 837
400 Troubleshooting of electrical system (E-mode) 839
E-1 Engine does not start 841
E-2 Preheater does not operate normally 848
E-3 Defective boom kick-out function and cancellation 852
E-4 Defective bucket positioner function and cancellation 856
E-5 Defective lift arm FLOATING holding function and cancellation 860
E-6 Travel direction selection system does not function 864
E-7 Wiper does not operate 868
E-8 Windshield washer does not operate 872
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off 876
E-10 Working lamp does not light up or go off 884
E-11 Turn signal lamp and hazard lamp do not light up or go off 889
E-12 Brake lamp does not light or it keeps lighting up 896
E-13 Backup lamp does not light or it keeps lighting up 898
E-14 Backup alarm does not sound or it keeps sounding 901
E-15 Horn does not sound or it keeps sounding 904
E-16 Alarm buzzer does not sound or it keeps sounding 906
E-17 Air conditioner does not operate or stop 908
E-18 The KOMTRAX system does not work properly 911
500 Troubleshooting of hydraulic and mechanical system (H-mode) 915
Method of using troubleshooting chart 917
Failure code and cause table 920
H-1 The machine does not start 922
H-2 The travel speed is slow 923
H-3 The traction force is weak 924
H-4 Engine stalls when traveling or engine speed drops excessively 925
H-5 The gear is not shifted 926
H-6 The steering wheel does not turn 927
H-7 The steering wheel is heavy 928
H-8 Steering wheel shakes or jerks 929
H-9 Machine deviates naturally to one side when traveling 929
H-10 The brake does not work or does not work well 930
H-11 The brake is not released or is dragged 931
H-12 The lift arm does not rise or lower 932
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 933
H-14 When rising, the lift arm comes to move slowly at specific height 934
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) 934
H-16 Hydraulic drifts of the lift arm occur often 934
H-17 The lift arm wobbles during operation 934
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily 935
H-19 The bucket does not tilt back 936
H-20 The bucket moves slowly or the tilting-back force is insufficient 937
H-21 The bucket comes to operate slowly in the midst of tilting-back 938
H-22 The bucket cylinder cannot hold down the bucket 938
H-23 Hydraulic drifts of the bucket occur often 938
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) 938
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily 939
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy 939
H-27 The ECSS does not operate and machine pitches and bounces 940
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 941
600 Troubleshooting of engine (S-mode) 943
Method of using troubleshooting charts 944
S-1 Starting performance is poor 948
S-2 Engine does not start 949
S-3 Engine does not pick up smoothly 952
S-4 Engine stops during operations 953
S-5 Engine does not rotate smoothly 954
S-6 Engine lacks output (or lacks power) 955
S-7 Exhaust smoke is black (incomplete combustion) 956
S-8 Oil consumption is excessive (or exhaust smoke is blue) 957
S-9 Oil becomes contaminated quickly 958
S-10 Fuel consumption is excessive 959
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 960
S-12 Oil pressure drops 961
S-13 Oil level rises (Entry of coolant or fuel) 962
S-14 Coolant temperature becomes too high (overheating) 963
S-15 Abnormal noise is made 964
S-16 Vibration is excessive 965
50 Disassembly and assembly 967
100 General information on disassembly and assembly 967
How to read this manual 968
Coating materials list 970
Special tool list 973
Sketches of special tools 977
200 Engine and cooling system 987
Removal and installation of fuel supply pump assembly 988
Removal and installation of fuel injector assembly 991
Removal and installation of cylinder head assembly 998
Removal and installation of engine hood assembly 1011
Removal and installation of radiator 1015
Removal and installation of air aftercooler 1018
Removal and installation of hydraulic oil cooler assembly 1020
Removal and installation of engine assembly 1022
Removal and installation of engine front oil seal assembly 1029
Removal and installation of engine rear oil seal assembly 1032
Removal and installation of cooling fan and fan motor assembly 1035
Removal and installation of fuel tank assembly 1038
310 Power train, Part 1 1041
Disassembly and assembly of transfer assembly 1042
Removal and installation of parking brake assembly 1061
Disassembly and assembly of parking brake assembly 1063
320 Power train, Part 2 1069
Removal and installation of front axle assembly 1070
Removal and installation of rear axle assembly 1072
Disassembly and assembly of axle housing assembly 1075
Disassembly and assembly of differential assembly 1083
400 Undercarriage and frame 1111
Removal and installation of center hinge pin 1112
Removal and installation of counterweight assembly 1121
500 Hydraulic system 1123
Removal and installation of HST pump and 4-gear pump assembly 1124
Disassembly and assembly of HST pump assembly 1128
Removal and installation of HST motor 1 assembly 1155
Removal and installation of HST motor 2 assembly 1157
Disassembly and assembly of HST motor assembly 1159
Removal and installation of work equipment control valve assembly 1175
Removal and installation of hydraulic tank 1177
Disassembly and assembly of hydraulic cylinder assembly 1179
600 Work equipment 1185
Removal and installation of work equipment assembly 1186
700 Cab and its attachments 1193
Removal and installation of operator’s cab and floor frame assembly 1194
Removal and installation of operator’s cab glass (Stuck glass) 1199
Removal and installation of air conditioner unit 1207
800 Electrical system 1213
Removal and installation of monitor panel 1214
Removal and installation of engine controller assembly 1216
Removal and installation of HST controller assembly 1218
Removal and installation of KOMTRAX terminal assembly 1219
90 Diagrams and drawings 1221
100 Hydraulic diagrams and drawings 1221
Central lubrication system 1222
Hydraulic circuit diagram WA200-6 1223
Hydraulic circuit diagram WA250PZ-6 1224
200 Electrical diagrams and drawings 1225
Electrical circuit diagram (1/9) 1227
Electrical circuit diagram (2/9) 1228
Electrical circuit diagram (3/9) 1229
Electrical circuit diagram (4/9) 1230
Electrical circuit diagram (5/9) 1231
Electrical circuit diagram (6/9) 1232
Electrical circuit diagram (7/9) 1233
Electrical circuit diagram (8/9) 1234
Electrical circuit diagram (9/9) 1235
Electrical circuit diagram 1236
Connector list and stereogram 1237

DESCRIPTION:

Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual VEBM600101 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
WA200-6                    75001 and up
WA200PZ-6               70136 and up
H00051 and up

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 26/12/24