Komatsu WA200-7 Wheel Loader Shop Manual VENBM29500 PDF

Description

Komatsu WA200-7 Wheel Loader Shop Manual VENBM29500 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA200-7 Wheel Loader Shop Manual VENBM29500 – PDF DOWNLOAD 

Language : English
Pages : 1552
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu WA200-7 Wheel Loader Shop Manual VENBM29500 – PDF DOWNLOAD 

VENBM29500 WA200-7 1
00 Index and foreword 3
Index and foreword 4
Index 4
Foreword, safety and general information 16
Important safety notice 16
Precautions to prevent fire 21
Action if fire occurs 22
Dispose of waste materials 22
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of Abbreviation 57
Conversion table 61
01 Specifications 67
Specifications 70
Specification dimension drawing 70
Specifications 72
Weight table 80
Table of fuel, coolant, and lubricants 84
10 Structure and function 87
Engine and cooling system 90
VFT 90
EGR system piping drawing 94
EGR system circuit diagram 96
EGR valve 98
EGR cooler 100
KCCV layout drawing 102
KCCV ventilator 105
CDR valve 106
Forming of condensed water and emulsion 107
KDOC muffler 109
Damper 111
Cooling system 112
Cooling system hydraulic piping diagram 113
Cooling fan motor 114
Power train 123
Power train 123
Power train system diagram 124
Drive shaft 126
HST hydraulic piping diagram 127
HST pump 128
HST motor 136
Transfer 142
Clutch solenoid valve 148
Axle 149
Differential 151
Torque proportioning differential 154
Limited slip differential 155
Final drive 158
Steering system 161
Steering piping diagram 161
Orbitrol valve 162
Steering column 170
Priority valve 171
Emergency steering valve 174
Brake system 177
Brake piping diagram 177
Brake valve 178
Charge valve 182
Accumulator (for brake) 186
Slack adjuster 187
Brake 189
Parking brake control 192
Parking brake 193
Parking brake cylinder 194
Parking brake solenoid valve 195
Inching valve 197
Undercarriage and frame 198
Axle mount and center hinge pin 198
Hydraulic system 200
Hydraulic component layout 200
Work equipment control lever linkage 202
Hydraulic tank 203
Accumulator (for PPC circuit) 205
Work equipment control valve 206
PPC valve 219
Attachment EPC valve 225
Work equipment lock solenoid valve 226
ECSS valve 227
Accumulator (for ECSS) 229
2-way restrictor valve 230
Cushion valve 231
Accumulator (for oil cooler circuit) 232
Quadruple gear pump 233
Quick coupler solenoid valve 234
Work equipment 235
Work equipment linkage 235
Bucket 237
Bucket positioner and boom kick-out 238
Cab and its attachments 244
Cab 244
Electrical system 245
Machine monitor system 245
Machine monitor 250
Electrical system (HST controller system) 272
System component parts 288
HST controller 294
ECSS 298
KOMTRAX system 300
Engine starting circuit 303
Engine stopping circuit 305
Preheating system 306
Automatic preheating system 307
Manual preheating system 307
Engine output limit function 308
Automatic warm-up function 308
Parking brake control system 309
Multi-function mono-lever 313
Sensor 315
20 Standard value table 331
Standard value table 333
Standard value table for engine 333
Standard value table for machine 335
30 Testing and adjusting 343
Related information on testing and adjusting 346
Tools for testing and adjusting 346
Engine and cooling system 349
Testing and adjusting engine speed 349
Testing exhaust gas temperature 351
Testing exhaust gas color 352
Testing and adjusting valve clearance 354
Testing compression pressure 356
Testing blowby pressure 359
Testing engine oil pressure 360
Testing boost pressure 361
Handling equipment of fuel system devices 363
Releasing remaining pressure from fuel system 363
Testing fuel pressure 364
Testing fuel discharge, return and leakage 369
Bleeding air from fuel system 374
Testing fuel circuit for leakage 376
Handling cylinder cutout mode operation 377
Handling no-injection cranking operation 377
Testing KDPF and muffler stack for looseness and damage 378
Testing KDOC function 378
Testing installed condition of cylinder heads and manifolds 379
Testing engine piping for damage and looseness 379
Testing and adjusting air conditioner compressor belt tension 380
Replacing alternator belt 381
Power train 382
Testing oil leakage from axle final drive 382
Testing drive shaft for looseness, backlash, and damage 383
Testing accelerator pedal 384
Testing and adjusting HST oil pressure 386
Testing transfer clutch control pressure 391
Steering system 392
Testing directional lever 392
Testing and adjusting steering wheel 393
Testing work equipment control lever 395
Testing and adjusting steering circuit oil pressure 396
Bleeding air from steering circuit 398
Brake system 399
Testing brake pedal 399
Testing and adjusting brake pedal and linkage 400
Testing braking performance 401
Testing and adjusting accumulator charge pressure 402
Testing wheel brake oil pressure 404
Testing lowering of wheel brake pressure 405
Testing wear of wheel brake disc 408
Bleeding air from wheel brake circuit 409
Releasing remaining pressure in brake accumulator circuit 410
Testing parking brake performance 411
Testing parking brake release pressure 412
Method of releasing parking brake manually 413
Hydraulic system 414
Testing and adjusting cooling fan speed 414
Testing cooling fan pump circuit oil pressure 415
Testing work equipment PPC oil pressure 416
Testing and adjusting work equipment oil pressure 417
Bleeding air from each part 418
Releasing remaining pressure in hydraulic circuit 419
Work equipment 420
Testing and adjusting bucket positioner 420
Testing and adjusting boom kick-out switch 421
Checking the proximity switch working pilot lamp 422
Electrical system 423
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 423
Special functions of machine monitor 425
KOMTRAX terminal start-up procedure 479
Lamp indication of KOMTRAX terminal 482
Handling voltage circuit of controller 486
Test diodes 487
Pm Clinic 488
Pm Clinic service 488
40 Troubleshooting 491
Related information on troubleshooting 498
Points to remember when performing troubleshooting 498
How to proceed in troubleshooting 500
Checks before troubleshooting 502
Check procedure before troubleshooting 504
Walk-around check 504
Check according to the check procedure 505
Preparation for troubleshooting of electrical system 522
Classification and procedures of troubleshooting 527
Symptom and troubleshooting No 531
Information described in troubleshooting table 533
Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system 535
Connector list and layout 538
Connection table of connector by No of pins 551
T-box and T-adapter list 588
Fuse location table 592
Failure code list 595
Troubleshooting by failure code (Display of code) 603
Failure code [2F00MB] Malfunction of Parking Brake 603
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) 605
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) 607
Failure code [6091NX] HST Filter Clogging 609
Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output 611
Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output 613
Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output 615
Failure code [989FN1] Travel Speed Overrun Alarm 617
Failure code [AB00L6] Discharge of Alternator R Terminal 618
Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery Charging 620
Failure code [B@BAZG] Engine Oil Pressure Low 622
Failure code [B@BCNS] Engine Water Overheat 623
Failure code [B@BCZK] Engine Coolant Level Low 624
Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm) 626
Failure code [B@CRNS] HST Oil Temperature Overheat 627
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 628
Failure code [CA122] Charge Air Pressure Sensor High Error 629
Failure code [CA123] Charge Air Pressure Sensor Low Error 631
Failure code [CA131] Throttle Sensor High Error 633
Failure code [CA132] Throttle Sensor Low Error 635
Failure code [CA144] Coolant Temperature Sensor High Error 637
Failure code [CA145] Coolant Temperature Sensor Low Error 639
Failure code [CA153] Charge Air Temperature Sensor High Error 641
Failure code [CA154] Chg Air Temp Sensor Low Error 643
Failure code [CA187] Sensor 2 Supply Voltage Low Error 645
Failure code [CA221] Ambient Pressure Sensor High Error 647
Failure code [CA222] Ambient Pressure Sensor Low Error 649
Failure code [CA227] Sensor 2 Supply Voltage High Error 651
Failure code [CA234] Engine Overspeed 652
Failure code [CA238] Ne Speed Sensor Supply Volt Error 653
Failure code [CA239] Ne Speed Sens Supply Volt High Error 654
Failure code [CA271] IMV/PCV1 Short Error 655
Failure code [CA272] IMV/PCV1 Open Error 657
Failure code [CA322] Injector #1 (L#1) Open/Short Error 659
Failure code [CA324] Injector #3 (L#3) Open/Short Error 661
Failure code [CA331] Injector #2 (L#2) Open/Short Error 663
Failure code [CA332] Injector #4 (L#4) Open/Short Error 665
Failure code [CA343] Engine Controller Internal Failure 667
Failure code [CA351] Injectors Drive Circuit Error 668
Failure code [CA352] Sensor 1 Supply Voltage Low Error 669
Failure code [CA356] Mass Air Flow Sensor High Error 671
Failure code [CA357] Mass Air Flow Sensor Low Error 673
Failure code [CA386] Sensor 1 Supply Voltage High Error 675
Failure code [CA428] Water in Fuel Sensor High Error 676
Failure code [CA429] Water in Fuel Sensor Low Error 678
Failure code [CA431] Idle Validation Sw Error 680
Failure code [CA432] Idle Validation Process Error 683
Failure code [CA435] Engine Oil Pressure Sw Error 685
Failure code [CA441] Battery Voltage Low Error 686
Failure code [CA442] Battery Voltage High Error 688
Failure code [CA449] Rail Press Very High Error 689
Failure code [CA451] Common Rail Pressure Sensor High Error 690
Failure code [CA452] Common Rail Pressure Sensor Low Error 692
Failure code [CA466] KVGT Motor Driver Position Error 694
Failure code [CA488] Chg Air Temp High Torque Derate 696
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error 697
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error 699
Failure code [CA553] Common Rail Pressure High Error 1 701
Failure code [CA555] Crankcase Press High Error 1 702
Failure code [CA556] Crankcase Press High Error 2 703
Failure code [CA559] Rail Press Low Error 1 704
Failure code [CA689] Engine Ne Speed Sensor Error 707
Failure code [CA691] Intake Air Temp Sens High Error 709
Failure code [CA692] Intake Air Temp Sens Low Error 711
Failure code [CA697] ECM Internal Temperature Sensor High Error 713
Failure code [CA698] EMC Internal Temperature Sensor Low Error 714
Failure code [CA731] Engine Bkup Speed Sensor Phase Error 715
Failure code [CA778] Engine Bkup Speed Sensor Error 717
Failure code [CA1117] Persistent Data Lost Error 722
Failure code [CA1695] Sensor 5 Supply Voltage High Error 723
Failure code [CA1696] Sensor 5 Supply Voltage Low Error 724
Failure code [CA1843] Crankcase Press Sens High Error 725
Failure code [CA1844] Crankcase Press Sens Low Error 727
Failure code [CA1896] EGR Valve Stuck Error 729
Failure code [CA1942] Crankcase Press Sens In-Range Error 730
Failure code [CA1961] EGR Motor Driver IC Over Temp Error 731
Failure code [CA2185] Throttle Sensor Supply Voltage High Error 732
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error 734
Failure code [CA2249] Rail Press Low Error 2 736
Failure code [CA2272] EGR Valve Position Sensor Low Error 737
Failure code [CA2311] IMV Solenoid Error 739
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error 740
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error 742
Failure code [CA2357] EGR Valve Servo Error 744
Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error 745
Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error 747
Failure code [CA2375] EGR Orifice Temperature Sensor High Error 749
Failure code [CA2376] EGR Orifice Temperature Sensor Low Error 751
Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error 753
Failure code [CA2555] Grid Heater Relay Voltage Low Error 754
Failure code [CA2556] Grid Heater Relay Voltage High Error 756
Failure code [CA2961] EGR Orifice Temperature High Error 1 758
Failure code [CA2973] Charge Air Pressure Sensor In-Range Error 759
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 760
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 762
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 764
Failure code [CA3741] Common Rail Pressure Valve Trip Error 766
Failure code [CA3918] KVGT Stuck Error 767
Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error 768
Failure code [CA3921] KVGT Servo Error 2 769
Failure code [CA3922] KVGT Motor Driver Open Error 770
Failure code [CA3923] KVGT Motor Driver Short Error 772
Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line 774
Failure code [D160KA] Disconnection of Backup Lamp Relay Output 776
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output 778
Failure code [D160KY] Hot Short of Backup Lamp Relay Output 780
Failure code [D191KA] Disconnection of Neutral Output Relay 782
Failure code [D191KB] Ground Fault of Neutral Output Relay 784
Failure code [D191KY] Hot Short of Neutral Output Relay 786
Failure code [D192KA] Disconnection of ECSS Solenoid Relay 788
Failure code [D192KB] Ground Fault of ECSS Solenoid Relay 790
Failure code [D192KY] Hot Short of ECSS Solenoid Relay 792
Failure code [D1B0KA] Disconnection of HST Safety Relay 794
Failure code [D1B0KB] Ground Fault of HST Safety Relay 796
Failure code [D1B0KY] Hot Short of HST Safety Relay 798
Failure code [D1B0MC] Malfunction of HST Safety Relay 800
Failure code [D1E6KA] Disconnection of Parking Brake Relay 801
Failure code [D1E6KB] Ground Fault of Parking Brake Relay 803
Failure code [D1E6KY] Hot Short of Parking Brake Relay 805
Failure code [D5ZHKA] Failure of Key SW C Signal 807
Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit 809
Failure code [D5ZHL6] Disconnection of Key SW C 811
Failure code [DAF3KK] Controller Power Source Low (MON) 813
Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault 815
Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault 817
Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor) 819
Failure code [DAJ0KK] Controller Power Source Low (HST) 820
Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST) 823
Failure code [DAJ0MC] HST Controller Malfunction 824
Failure code [DAJ1KA] Disconnection of Key SW ACC (HST) 825
Failure code [DAJ2KK] Solenoid Power Source Low (HST) 827
Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST) 830
Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST) 832
Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST) 834
Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST) 836
Failure code [DAJ9KQ] Inconsistency of Model Selection (HST) 838
Failure code [DAJLKA] Operating Lamp Open Circuit (HST) 839
Failure code [DAJLKB] Operating Lamp Short Circuit (HST) 841
Failure code [DAJQKR] CAN2 Disconnection (HST) 843
Failure code [DAJRMA] Inconsistency of Option Selection (HST) 844
Failure code [DB2QKR] CAN2 Disconnection (Engine Controller) 845
Failure code [DB2RKR] CAN1 Disconnection (Engine Controller) 849
Failure code [DBE6KX] 24V Output Power Supply System Failure 852
Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error 854
Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal 856
Failure code [DDB6L4] Parking Brake Signal Malfunction 858
Failure code [DDD7KA] Failure of Variable Speed Control 860
Failure code [DDD7KY] Hot Short of Variable Speed Control 862
Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch) 864
Failure code [DDK3KA] FNR SW Input Signal Disconnection 866
Failure code [DDK3KB] FNR SW Input Signal Short Circuit 868
Failure code [DDK6KA] FNR Lever Input Signal Disconnection 870
Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short) 872
Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch 874
Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control) 876
Failure code [DF10KA] Disconnection of Speed Range Input Switch 878
Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short) 883
Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground 888
Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor 890
Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor 892
Failure code [DHH1KX] Failure of HST Oil Pressure Sensor 894
Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor 896
Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom) 898
Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head) 900
Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure 902
Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor 904
Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main) 906
Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main) 909
Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree 911
Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub) 914
Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub) 917
Failure code [DKA0KX] Failure of Boom Angle Sensor 919
Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor 921
Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor 923
Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B) 924
Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A) 926
Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B) 928
Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B) 931
Failure code [DT22KB] Ground Fault of Work Equip Lock Indicator 933
Failure code [DV00KY] Hot Short of Alarm Buzzer 935
Failure code [DW26KA] Open Circuit of Motor 2 Solenoid 937
Failure code [DW26KB] Ground Fault of Motor 2 Solenoid 939
Failure code [DW26KY] Hot Short of Motor 2 Solenoid 941
Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid 943
Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid 945
Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid 947
Failure code [DX19KA] Disconnection of Motor 1 Solenoid 949
Failure code [DX19KB] Ground Fault of Motor 1 Solenoid 952
Failure code [DX19KY] Hot Short of Motor 1 Solenoid 954
Failure code [DX20KA] Disconnection of Clutch EPC Solenoid 956
Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid 959
Failure code [DX20KY] Hot Short of Clutch EPC Solenoid 961
Failure code [DXH7KA] Disconnection of Reverse Solenoid 963
Failure code [DXH7KB] Ground Fault of Reverse Solenoid 965
Failure code [DXH7KY] Hot Short of Reverse Solenoid 967
Failure code [DXH8KA] Disconnection of Forward Solenoid 968
Failure code [DXH8KB] Ground Fault of Forward Solenoid 970
Failure code [DXH8KY] Hot Short of Forward Solenoid 972
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) 973
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) 975
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) 977
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) 978
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) 980
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) 982
Failure code [H2K0KA] Failure of Quick Coupler Lock Signal 983
Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal 986
Failure code [J141N1] Steering Pump Over Run 988
Failure code [LA00L3] Failure of Fan Reverse 989
Failure code [M100N1] HST Pump Over Run 990
Failure code [M400N1] HST Motor 1 Over Run 991
Troubleshooting of electrical system (E-mode) 992
E-1 Engine does not start 992
E-2 Manual preheating system does not work 997
E-3 Automatic preheating system does not work 1000
E-4 While preheating is working, preheating monitor does not light up 1002
E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor 1004
E-6 Travel speed is slow 1007
E-7 ECSS does not operate 1009
E-8 ECSS remains being operated 1012
E-9 Boom kick-out does not work or is not reset 1015
E-10 Bucket positioner does not work or is not reset 1018
E-11 Boom FLOAT holding does not work or is not reset 1021
E-12 Directional selection does not work normally 1024
E-13 Fan does not rotate in reverse 1035
E-14 Fan remains in reverse rotation mode 1038
E-15 Wipers do not operate 1040
E-16 Window washer does not operate 1045
E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out 1048
E-18 Working lamp does not light up or does not go out 1057
E-19 Turn signal and hazard lamp do not light up or do not go out 1062
E-20 Stop lamp does not light up or remains lighting up 1069
E-21 Backup lamp does not light up or remains lighting up 1072
E-22 Backup alarm does not sound or does not stop sounding 1075
E-23 Horn does not sound or does not stop sounding 1077
E-24 Alarm buzzer does not sound or does not stop sounding 1080
E-25 KOMTRAX system does not operate normally 1082
E-26 Fuel gauge does not indicate correct level 1084
E-27 Seat belt caution lamp indication is incorrect 1086
Troubleshooting for hydraulic and mechanical system (H-mode) 1087
Information described in troubleshooting table (H-mode) 1087
System chart of hydraulic and mechanical systems 1088
Failure mode and cause table 1090
H-1 Machine travels neither forward nor in reverse 1096
H-2 Machine does not travel forward (normally travels in reverse) 1098
H-3 Machine does not travel in reverse (normally travels forward) 1099
H-4 Both forward and reverse travel speeds are low 1100
H-5 Forward travel speed is low (normal when traveling in reverse) 1102
H-6 Reverse travel speed is low (normal when traveling forward) 1103
H-7 Machine lacks power when traveling both forward and in reverse 1104
H-8 Machine lacks power when traveling forward (normal when traveling in reverse) 1106
H-9 Machine lacks power when traveling in reverse (normal when traveling forward) 1107
H-10 Engine stalls during travel or engine speed drops significantly 1108
H-11 Machine does not turn 1109
H-12 Steering wheel is heavy to turn 1111
H-13 Machine sways or large shocks are made while machine turns 1112
H-14 Machine turns to either side unintentionally during traveling 1113
H-15 Brake does not work or it is weak 1114
H-16 Brake is not released or drags 1115
H-17 Parking brake does not work or it is weak 1116
H-18 Parking brake is not released or drags 1117
H-19 Boom does not rise 1118
H-20 Boom moves slow or lacks lifting force 1119
H-21 Boom rising speed lowers at certain height 1120
H-22 Lift cylinder cannot hold down bucket (bucket rises off ground) 1121
H-23 Hydraulic drift of boom is large 1122
H-24 Boom wobbles during operation 1126
H-25 Bucket does not tilt back 1127
H-26 Bucket moves slow or lacks tilting back force 1128
H-27 Bucket speed lowers in tilt-back motion 1129
H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground) 1130
H-29 Hydraulic drift of bucket is large 1131
H-30 Loaded bucket wobbles during travel (with work equipment valve at “HOLD”) 1132
H-31 Boom and bucket control levers do not move smoothly and are heavy to move 1133
H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated 1134
H-33 Large shock is made when work equipment starts and stops 1135
H-34 When certain work equipment is relieved hydraulically, other work equipment moves 1136
H-35 ECSS does not operate and machine pitches and bounds 1137
H-36 Fan speed is abnormal (too high or low, or fan does not rotate) 1138
H-37 Unusual noise is heard from around fan 1140
Troubleshooting of engine (S-mode) 1141
Information mentioned in troubleshooting table (S mode) 1141
S-1 Engine does not crank when starting switch is turned to START position 1142
S-2 Engine cranks but no exhaust smoke comes out 1143
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1144
S-4 Engine startability is poor 1145
S-5 Engine does not pick up smoothly 1147
S-6 Engine stops during operation 1149
S-7 Engine runs rough or is unstable 1150
S-8 Engine lacks power 1151
S-9 Exhaust smoke is black 1153
S-10 Engine oil consumption is excessive 1155
S-11 Oil becomes contaminated quickly 1156
S-12 Fuel consumption is excessive 1157
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1158
S-14 Oil pressure drops 1159
S-15 Fuel mixes into engine oil 1160
S-16 Water mixes into engine oil (milky) 1161
S-17 Coolant temperature rises too high (overheating) 1162
S-18 Unusual noise is heard 1163
S-19 Vibration is excessive 1164
S-20 Air cannot be bled from fuel circuit 1165
50 Disassembly and assembly 1167
General information on disassembly and assembly 1170
How to read this manual 1170
Coating materials list 1172
Special tool list 1176
Sketches of special tools 1180
Engine and cooling system 1190
Removal and installation of fuel supply pump assembly 1190
Removal and installation of fuel injector assembly 1194
Removal and installation of engine hood assembly 1202
Removal and installation of cylinder head assembly 1205
Removal and installation of radiator assembly 1216
Removal and installation of air aftercooler assembly 1219
Removal and installation of hydraulic oil cooler assembly 1221
Removal and installation of engine assembly 1223
Removal and installation of belt for alternator and air conditioner compressor 1228
Removal and installation of engine front oil seal assembly 1230
Removal and installation of engine rear oil seal assembly 1234
Removal and installation of cooling fan and fan motor assembly 1238
Removal and installation of fuel tank assembly 1241
Removal and installation of KCCV ventilator assembly 1243
Removal and installation of KDOC muffler 1244
Removal and installation of EGR cooler assembly 1245
Removal and installation of EGR valve assembly 1247
Power train 1249
Removal and installation of transfer assembly 1249
Disassembly and assembly of transfer assembly 1253
Removal and installation of parking brake assembly 1276
Removal and installation of parking brake cylinder assembly 1278
Disassembly and assembly of parking brake assembly 1279
Removal and installation of front axle assembly 1285
Removal and installation of rear axle assembly 1287
Disassembly and assembly of axle housing assembly 1290
Disassembly and assembly of differential assembly 1299
Undercarriage and frame 1324
Removal and installation of center hinge pin 1324
Removal and installation of counterweight assembly 1333
Hydraulic system 1336
Removal and installation of HST pump and quadruple type gear pump assembly 1336
Removal and installation of HST motor 1 assembly 1340
Removal and installation of HST motor 2 assembly 1342
Removal and installation of work equipment control valve assembly 1345
Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly 1347
Removal and installation of hydraulic tank assembly 1349
Disassembly and assembly of hydraulic cylinder assembly 1351
Work equipment 1355
Removal and installation of work equipment assembly 1355
Cab and its attachments 1361
Removal and installation of operator’s cab and floor frame assembly 1361
Removal and installation of operator’s cab glass (adhered glass) 1366
Disassembly and assembly of operator’s seat 1374
Removal and installation of air conditioner unit assembly 1384
Removal and installation of air conditioner compressor assembly 1390
Electrical system 1392
Removal and installation of machine monitor 1392
Removal and installation of engine controller assembly 1394
Removal and installation of HST controller assembly 1396
Removal and installation of KOMTRAX terminal assembly 1397
60 Maintenance standard 1399
Engine and cooling system 1401
Engine mount and transfer mount 1401
Damper 1402
Cooling system 1403
Cooling fan motor 1404
Power train 1406
Drive shaft 1406
Transfer 1407
Axle 1415
Differential 1417
Limited slip differential 1421
Final drive 1423
Steering system 1426
Orbitrol valve 1426
Steering cylinder 1427
Steering column 1429
Priority valve 1430
Emergency steering valve 1431
Brake system 1432
Charge valve 1432
Slack adjuster 1434
Brake 1435
Parking brake 1437
Undercarriage and frame 1438
Axle mount and center hinge pin 1438
Hydraulic system 1442
Hydraulic tank 1442
Work equipment control valve 1443
PPC valve 1449
ECSS valve 1452
Quadruple gear pump 1453
Work equipment 1455
Work equipment linkage 1455
Bucket 1457
Bucket positioner and boom kick-out 1458
Work equipment cylinder 1459
80 Appendix 1461
Air conditioner 1463
Precautions for refrigerant 1463
Air conditioner component 1464
Configuration and function of refrigeration cycle 1466
Outline of refrigeration cycle 1467
Air conditioner unit 1469
Functions of main components in air conditioner unit 1470
Blower and intake unit 1471
Compressor 1472
Condenser 1473
Receiver drier 1474
Air conditioner control panel 1475
Procedure for troubleshooting 1476
Circuit diagram and arrangement of connector pins 1478
System diagram 1480
Details of air conditioner unit 1482
Parts and connectors layout 1483
Inspection by self-diagnosis function (displays diagnosis on the control panel) 1485
Testing temperature control system 1486
Testing FRESH/RECIRC air changeover 1487
Testing evaporator temperature sensor 1489
Testing relays 1490
Troubleshooting chart 1 1491
Troubleshooting chart 2 1493
Information described in troubleshooting table 1496
Troubleshooting for power supply system (Air conditioner does not operate) 1497
Troubleshooting for compressor and refrigerant system (Air is not cooled) 1501
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1504
Troubleshooting for temperature control 1507
Troubleshooting for FRESH/RECIRC air changeover 1510
Connection of service tool 1512
Troubleshooting by gauge pressure 1514
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1517
Handling of compressor oil 1519
90 Diagrams and drawings 1523
Hydraulic diagrams and drawings 1525
Symbols used in hydraulic circuit diagrams 1525
Electrical diagrams and drawings 1528
Symbols used in electric circuit diagrams 1528
Electrical circuit diagram 0
Index 1543

DESCRIPTION:

Komatsu WA200-7 Wheel Loader Shop Manual VENBM29500 – PDF DOWNLOAD 

Composition of shop manual
q This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
q This section includes the index, foreword, safety and basic information.
01. Specification
q This section explains the specifications of the machine.
10. Structure and function
q This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as reference
material for troubleshooting.
20. Standard value table
q The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
q This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
q This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
q This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
q This section describes the maintenance standard values for each component. This section gives the criterion
values for each component and required remedy at disassembly or maintenance.
80. Appendix
q The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
q This section gives hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24