Komatsu WHEEL LOADER WA200 -6 WA200PZ-6 Shop Manual SEN05282-11 PDF

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Komatsu WHEEL LOADER WA200 -6 WA200PZ-6 Shop Manual SEN05282-11 – PDF DOWNLOAD

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Komatsu WHEEL LOADER WA200 -6 WA200PZ-6 Shop Manual SEN05282-11 – PDF DOWNLOAD

Language : English
Pages :1348
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu WHEEL LOADER WA200 -6 WA200PZ-6 Shop Manual SEN05282-11 – PDF DOWNLOAD

SERIAL NUMBERS WA200- 70001
WA200PZ-70001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu WHEEL LOADER WA200 -6 WA200PZ-6 Shop Manual SEN05282-11 – PDF DOWNLOAD

SERIAL NUMBERS WA200- 70001
WA200PZ-70001 and up

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 differential 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 159
Emergency steering valve 160
Steering relief valve 163
400 Brake system 165
Brake piping diagram 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
901 Electrical system, Part 1 303
Machine monitor system 304
Machine monitor 308
Rearview monitor system 329
902 Electrical system, Part 2 335
Electrical system (HST controller system) 336
HST controller 352
ECSS system 354
KOMTRAX system 356
Engine starting circuit 358
Engine stopping circuit 360
Preheating circuit 361
Engine output derating function 362
Automatic warm-up function 362
Parking brake circuit 364
Coupler plunger control system 366
Max traction switch 367
Multi-function knob 368
Sensor 369
20 Standard value table 377
100 Standard service value table 377
Standard service value table for engine 378
Standard service value table for chassis 379
30 Testing and adjusting 387
101 Testing and adjusting, Part 1 387
Precautions before work 389
Tools for testing, adjusting, and troubleshooting 390
Sketches of special tools 395
Measuring engine speed 396
Measuring exhaust gas color 398
Adjusting valve clearance 399
Measuring compression pressure 401
Measuring blow-by pressure 404
Testing engine oil pressure 405
Measuring intake air (boost) pressure 406
Handling fuel system equipment 408
Releasing residual pressure in fuel system 408
Measuring fuel pressure 409
Measuring fuel return rate and leakage 411
Bleeding air from fuel circuit 415
Checking leakage in fuel system 416
Handling cylinder cut-out mode operation 417
Handling no-injection cranking operation 417
Handling controller voltage circuit 418
Check of muffler and muffler stack for looseness and damage 418
Check of muffler function 419
Check of installed condition of cylinder head and manifolds 419
Check of engine piping for damage and looseness 420
Testing and adjusting air conditioner compressor belt tension 420
Replacing alternator belt 421
102 Testing and adjusting, Part 2 423
Checking operating force of accelerator pedal 425
Checking directional lever 426
Testing and adjusting HST oil pressure 427
Testing clutch control pressure 432
Testing and adjusting steering wheel 433
Testing and adjusting steering oil pressure 435
Bleeding air from steering circuit 437
Testing hydraulic fan 438
Measuring brake pedal 440
Testing and adjusting brake pedal linkage 441
Measuring brake performance 442
Testing and adjusting accumulator charge pressure 443
Testing wheel brake oil pressure 445
Testing wear of brake disc 448
Bleeding air from wheel brake circuit 449
Releasing residual pressure in brake accumulator circuit 450
Testing parking brake performance 451
Testing and adjusting parking brake control cable 452
Measuring and adjusting work equipment control lever 453
Testing and adjusting work equipment hydraulic pressure 454
Testing work equipment PPC oil pressure 455
Bleeding air from hydraulic circuit 457
Releasing remaining pressure in hydraulic circuit 458
Testing and adjusting bucket positioner 459
Testing and adjusting boom kick- out switch 461
Checking proximity switch operation pilot lamp 462
Procedure for testing diodes 463
Preparation work for troubleshooting for electric system 465
Starting KOMTRAX terminal operations 469
Indicator lamps of KOMTRAX terminal 473
Adjustment of rearview camera angle 476
103 Testing and adjusting, Part 3 479
Adjusting machine monitor 480
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 481
Special functions of machine monitor (EMMS) 483
Pm clinic inspection chart 537
40 Troubleshooting 541
100 Failure code table and fuse locations 541
Precautions before work 542
Failure codes table 543
Fuse locations 549
200 General information on troubleshooting 555
Points to remember when troubleshooting 556
Sequence of events in troubleshooting 557
Testing before troubleshooting 558
Classification and procedures of troubleshooting 559
Information contained in troubleshooting table 562
Connection table for connector pin numbers 564
T- branch box and T- branch adapter table 600
301 Troubleshooting by failure code (Display of code), Part 1 605
Failure code [2G40ZG] Brake: Oil pressure reduction 606
Failure code [6091NX] HST filter: Clogging 608
Failure code [989FN1] Travel speed: Overrun alarm 609
Failure code [AB00L6] Alternator R system: Hot short 610
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage 612
Failure code [B@BAZG] Engine: Oil pressure reduction 614
Failure code [B@BCNS] Engine: Overheat 615
Failure code [B@BCZK] Engine: Low coolant level 616
Failure code [B@C6NS] Front brake: High oil temperature 618
Failure code [B@CRNS] HST: High oil temperature 619
302 Troubleshooting by failure code (Display of code), Part 2 621
Failure code [CA111] Abnormality in engine controller 623
Failure code [CA115] Engine Ne or Bkup speed sensor error 624
Failure code [CA122] Charge pressure sensor high error 626
Failure code [CA123] Charge pressure sensor low error 628
Failure code [CA131] Throttle sensor high error 630
Failure code [CA132] Throttle sensor low error 632
Failure code [CA144] Coolant sensor high error 634
Failure code [CA145] Coolant sensor low error 636
Failure code [CA153] Charge temperature sensor high error 638
Failure code [CA154] Charge temperature sensor low error 640
Failure code [CA155] Derating of speed by abnormally high charge temperature 642
Failure code [CA187] Sensor power supply 2 low error 644
Failure code [CA221] Atmospheric pressure sensor high error 646
Failure code [CA222] Atmospheric sensor low error 648
Failure code [CA227] Sensor power supply 2 high error 650
Failure code [CA234] Engine overspeed 651
Failure code [CA238] Ne speed sensor power supply error 652
Failure code [CA271] IMV (IMA) Short circuit 653
Failure code [CA272] IMV (IMA) Disconnection 654
Failure code [CA322] Injector #1 open/short error 656
Failure code [CA324] Injector #3 open/short error 658
Failure code [CA331] Injector #2 open/short error 660
Failure code [CA332] Injector #4 open/short error 662
Failure code [CA342] Calibration code inconsistency 664
Failure code [CA351] Injectors drive circuit error 666
Failure code [CA352] Sensor power supply 1 low error 668
Failure code [CA386] Sensor power supply 1 high error 670
303 Troubleshooting by failure code (Display of code), Part 3 673
Failure code [CA428] Abnormally high level in water sensor 676
Failure code [CA429] Abnormally low level in water sensor 678
Failure code [CA431] Idle validation switch error 680
Failure code [CA432] Idle validation action error 684
Failure code [CA435] Engine oil pressure switch error 688
Failure code [CA441] Battery voltage low error 689
Failure code [CA442] Battery voltage high error 692
Failure code [CA449] Common rail pressure high error 2 694
Failure code [CA451] Common rail pressure sensor high error 696
Failure code [CA452] Common rail pressure sensor low error 698
Failure code [CA488] Derating of torque by abnormally high charge temperature 700
Failure code [CA553] Common rail pressure high error 1 701
Failure code [CA559] Supply pump pressure very low error 702
Failure code [CA689] Engine Ne speed sensor error 704
Failure code [CA731] Engine Bkup speed sensor phase error 706
Failure code [CA757] All continuous data lost error 707
Failure code [CA778] Engine Bkup speed sensor error 710
Failure code [CA1633] KOMNET datalink timeout error 712
Failure code [CA2185] Throttle sensor supply voltage high error 714
Failure code [CA2186] Throttle sensor power supply low error 716
Failure code [CA2249] Supply pump pressure very low error 2 718
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 720
Failure code [CA2555] Intake heater relay disconnection error 722
Failure code [CA2556] Intake heater relay short circuit error 724
304 Troubleshooting by failure code (Display of code), Part 4 727
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short 728
Failure code [D192KY] ECSS solenoid relay: Hot short 730
Failure code [D1B0KA] HST safety relay: Disconnection 732
Failure code [D1B0KB] HST safety relay: Ground fault 734
Failure code [D1B0KY] HST safety relay: Hot short 736
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection 738
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection 740
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection 742
Failure code [DAJ0KK] HST controller power supply: Low voltage 744
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality 746
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault 748
Failure code [DAJ1L6] HST controller main power line: Hot short 750
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage 752
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness 754
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault 756
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range 758
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals 760
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection 762
Failure code [DAJRMA] HST controller: Disagreement in option selection 767
305 Troubleshooting by failure code (Display of code), Part 5 769
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line 770
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality 776
Failure code [DD1NLD] Fan reverse switch signal: Abnormality 778
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short 780
Failure code [DDB6KB] Parking brake indicator signal: Ground fault 782
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble 784
Failure code [DDB6L0] Parking brake reminder signal: Ground fault 786
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short 788
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault 790
Failure code [DDD7KY] Travel speed control dial signal: Hot short 792
Failure code [DDE5MA] Emergency steering operation switch: Disconnection 794
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault 796
Failure code [DDK6KY] FNR lever: Hot short 800
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) 802
306 Troubleshooting by failure code (Display of code), Part 6 805
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault 806
Failure code [DF10KB] Travel speed range selector switch: Hot short 810
Failure code [DGH1KX] HST oil temperature sensor: Ground fault 812
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault 813
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short 814
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault 816
Failure code [DHH1KY] HST oil pressure sensor: Hot short 818
Failure code [DHTCL6] HST filter clogging sensor: Functional defect 820
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short 822
Failure code [DLT3KX] Travel speed sensor B: Abnormality 824
Failure code [DLT4KX] Travel speed sensor A: Abnormality 828
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality 830
Failure code [DV00KY] Alarm buzzer: Hot short 832
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault 834
Failure code [DW26KY] Motor 2 solenoid: Hot short 836
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short 838
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault 840
307 Troubleshooting by failure code (Display of code), Part 7 843
Failure code [DX16KA] Fan EPC solenoid: Disconnection 844
Failure code [DX16KB] Fan EPC solenoid: Ground fault 845
Failure code [DX16KY] Fan EPC solenoid: Hot short 846
Failure code [DX19KA] Motor 1 solenoid: Disconnection 848
Failure code [DX19KB] Motor 1 solenoid: Ground fault 850
Failure code [DX19KY] Motor 1 solenoid: Hot short 852
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 854
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 856
Failure code [DX20KY] Clutch EPC solenoid: Hot short 858
Failure code [DXH7KB] Reverse solenoid: Ground fault 860
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 862
Failure code [DXH8KB] Forward solenoid: Ground fault 864
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 866
Failure code [J141N1] Steering pump: Overrun alarm 868
Failure code [M100N1] HST pump: Overrun alarm 869
Failure code [M400N1] Motor 1: Overrun alarm 870
400 Troubleshooting of electrical system (E-mode) 873
E-1 Engine does not start 875
E-2 Preheater does not operate normally 882
E-3 Travel speed is low or high 886
E-4 ECSS does not operate 892
E-5 ECSS keeps operating 895
E-6 Defective boom kick-out function and cancellation 898
E-7 Defective bucket positioner function and cancellation 902
E-8 Defective lift arm FLOATING holding function and cancellation 906
E-9 Travel direction selection system does not function 910
E-10 Fan does not reverse 914
E-11 Fan keeps rotating in reverse 918
E-12 Wiper does not operate 920
E-13 Windshield washer does not operate 924
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off 928
E-15 Working lamp does not light up or go off 936
E-16 Turn signal lamp and hazard lamp do not light up or go off 941
E-17 Brake lamp does not light or it keeps lighting up 948
E-18 Backup lamp does not light or it keeps lighting up 950
E-19 Backup alarm does not sound or it keeps sounding 953
E-20 Horn does not sound or it keeps sounding 956
E-21 Alarm buzzer does not sound or it keeps sounding 958
E-22 Air conditioner does not operate or stop 961
E-23 The KOMTRAX system does not work properly 964
E-24 Rearview monitor does not light up or backlight flickers 966
E-25 Rearview monitor images are not displayed clearly 970
E-26 Rearview monitor brightness cannot be adjusted 974
E-27 Night lighting lamp of rearview monitor is abnormal 978
E-28 Reverse interlock function of rearview monitor does not operate properly 981
500 Troubleshooting of hydraulic and mechanical system (H-mode) 985
Method of using troubleshooting chart 987
Failure code and cause table 990
H-1 The machine does not start 992
H-2 The travel speed is slow 993
H-3 The traction force is weak 994
H-4 Engine stalls when traveling or engine speed drops excessively 995
H-5 Speed range is not shifted 996
H-6 The steering wheel does not turn 997
H-7 The steering wheel is heavy 998
H-8 Steering wheel shakes or jerks 999
H-9 Machine deviates naturally to one side when traveling 999
H-10 The brake does not work or does not work well1000
H-11 The brake is not released or is dragged1001
H-12 The lift arm does not rise or lower1002
H-13 The lift arm moves slowly or the lift arm rising force is insufficient1003
H-14 When rising, the lift arm comes to move slowly at specific height1004
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)1004
H-16 Hydraulic drifts of the lift arm occur often1004
H-17 The lift arm wobbles during operation1004
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily1005
H-19 The bucket does not tilt back1006
H-20 The bucket moves slowly or the tilting-back force is insufficient1007
H-21 The bucket comes to operate slowly in the midst of tilting-back1008
H-22 The bucket cylinder cannot hold down the bucket1008
H-23 Hydraulic drifts of the bucket occur often1008
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)1008
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily1009
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy1009
H-27 The ECSS does not operate and machine pitches and bounces1010
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)1011
600 Troubleshooting of engine (S-mode)1013
Method of using troubleshooting charts1014
S-1 Starting performance is poor1018
S-2 Engine does not start1019
S-3 Engine does not pick up smoothly1022
S-4 Engine stops during operations1023
S-5 Engine does not rotate smoothly1024
S-6 Engine lacks output (or lacks power)1025
S-7 Exhaust smoke is black (incomplete combustion)1026
S-8 Oil consumption is excessive (or exhaust smoke is blue)1027
S-9 Oil becomes contaminated quickly1028
S-10 Fuel consumption is excessive1029
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1030
S-12 Oil pressure drops1031
S-13 Oil level rises (Entry of coolant or fuel)1032
S-14 Coolant temperature becomes too high (overheating)1033
S-15 Abnormal noise is made1034
S-16 Vibration is excessive1035
50 Disassembly and assembly1037
100 General information on disassembly and assembly1037
Precautions before work1038
How to read this manual1039
Coating materials list1041
Special tool list1044
Sketches of special tools1048
200 Engine and cooling system1059
Removal and installation of fuel supply pump assembly1060
Removal and installation of fuel injector assembly1064
Removal and installation of cylinder head assembly1072
Removal and installation of engine hood assembly1086
Removal and installation of radiator1090
Removal and installation of air aftercooler1093
Removal and installation of hydraulic oil cooler assembly1095
Removal and installation of engine assembly1097
Removal and installation of engine front oil seal assembly1104
Removal and installation of engine rear oil seal assembly1107
Removal and installation of cooling fan and fan motor assembly1110
Removal and installation of fuel tank assembly1113
301 Power train, Part 11117
Disassembly and assembly of transfer assembly1118
Removal and installation of parking brake assembly1138
Disassembly and assembly of parking brake assembly1140
302 Power train, Part 21147
Removal and installation of front axle assembly1148
Removal and installation of rear axle assembly1150
Disassembly and assembly of axle housing assembly1153
Disassembly and assembly of differential assembly1161
400 Undercarriage and frame1189
Removal and installation of center hinge pin1190
Removal and installation of counterweight assembly1199
500 Hydraulic system1203
Removal and installation of HST pump and 4-gear pump assembly1204
Disassembly and assembly of HST pump assembly1208
Removal and installation of HST motor 1 assembly1235
Removal and installation of HST motor 2 assembly1237
Disassembly and assembly of HST motor assembly1239
Removal and installation of work equipment control valve assembly1255
Removal and installation of hydraulic tank1257
Disassembly and assembly of hydraulic cylinder assembly1259
600 Work equipment1265
Removal and installation of work equipment assembly1266
700 Cab and its attachments1275
Removal and installation of operator’s cab and floor frame assembly1276
Removal and installation of operator’s cab glass (Stuck glass)1281
Removal and installation of air conditioner unit1289
800 Electrical system1297
Removal and installation of monitor panel1298
Removal and installation of engine controller assembly1300
Removal and installation of HST controller assembly1302
Removal and installation of KOMTRAX terminal assembly1303
90 Diagrams and drawings1305
100 Hydraulic diagrams and drawings1305
Hydraulic circuit diagram1307
200 Electrical diagrams and drawings1313
Common electrical circuit diagram1315
Specific electrical circuit diagram1343
Connector list and stereogram1345

S.M 29/12/24