Komatsu Wheel Loader WA200 WA200PZ WA200-5 WA200-6 WA200PZ-6 WA200L-5 Workshop Repair Service Manual PDF - MKMTSWA200PZ.zip
A full factory-style service and repair guide, complete with Electrical Wiring Diagrams, for the Komatsu WA200 and WA200PZ Wheel Loaders — everything you need to service, troubleshoot, fix, and rebuild your machine the way professional technicians do.
This workshop service and repair manual for the Komatsu WA200 and WA200PZ Wheel Loaders contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN03862-05 - Wheel Loader WA200-6, WA200PZ-6 Shop Manual.pdf
TEN00211-01 - Wheel Loader WA200-5 Operation & Maintenance Manual.pdf
TEN00212-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual.pdf
TEN00264-05 - Wheel Loader WA200PZ-6 Operation & Maintenance Manual.pdf
TEN00407-02 - Wheel Loader WA200PZ-6 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,311 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
SEN03862-05 - Wheel Loader WA200-6, WA200PZ-6 Shop Manual.....2
COVER.....2
00 INDEX AND FOREWORD.....0
100 Index.....4
Composition of shop manual.....5
Table of contents.....7
200 FOREWORD AND GENERAL INFORMATION.....18
SAFETY NOTICE.....19
HOW TO READ THE SHOP MANUAL.....24
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.....26
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT.....28
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES.....37
HOW TO READ ELECTRIC WIRE CODE.....40
PRECAUTIONS WHEN CARRYING OUT OPERATION.....43
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER.....46
STANDARD TIGHTENING TORQUE TABLE.....49
CONVERSION TABLE.....53
01 SPECIFICATION.....0
100 SPECIFICATION AND TECHNICAL DATA.....60
SPECIFICATION DIMENSION DRAWING.....62
SPECIFICATIONS.....63
WEIGHT TABLE.....67
TABLE OF FUEL, COOLANT AND LUBRICANTS.....69
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.....0
100 ENGINE AND COOLING SYSTEM.....72
ENGINE MOUNT AND TRANSFER MOUNT.....73
DAMPER.....74
COOLING SYSTEM.....75
COOLING SYSTEM HYDRAULIC PIPING DIAGRAM.....76
COOLING FAN MOTOR.....78
200 POWER TRAIN.....88
POWER TRAIN.....90
POWER TRAIN SYSTEM DIAGRAM.....91
DRIVE SHAFT.....93
HST HYDRAULIC PIPING DIAGRAM.....94
HST PUMP.....95
HST MOTOR.....103
TRANSFER.....109
CLUTCH SOLENOID VALVE.....120
AXLE.....121
DIFFERENTIAL.....123
TORQUE PROPORTIONING.....128
LIMITED SLIP DIFFERENTIAL.....131
FINAL DRIVE.....135
300 STEERING SYSTEM.....140
STEERING PIPING DIAGRAM.....142
STEERING COLUMN.....143
PRIORITY VALVE.....144
ORBIT-ROLL VALVE.....147
2-WAY RESTRICTOR VALVE.....155
CUSHION VALVE.....156
STEERING CYLINDER.....157
EMERGENCY STEERING PIPING DIAGRAM.....159
EMERGENCY STEERING VALVE.....160
STEERING RELIEF VALVE.....163
400 BRAKE SYSTEM.....166
BRAKE PIPING DIAGRA.....168
CHARGE VALVE.....169
BRAKE VALVE.....173
INCHING VALVE.....177
ACCUMULATOR (FOR BRAKE).....178
SLACK ADJUSTER.....179
BRAKE.....181
PARKING BRAKE CONTROL.....186
PARKING BRAKE.....187
500 UNDERCARRIAGE AND FRAME.....190
AXLE MOUNT AND CENTER HINGE PIN.....191
TIRES.....196
600 HYDRAULIC SYSTEM.....198
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM.....199
WORK EQUIPMENT CONTROL LEVER LINKAGE.....203
HYDRAULIC TANK.....207
4-GEAR PUMP.....209
WORK EQUIPMENT CONTROL VALVE .....212
PPC VALVE.....236
LOCK VALVE.....251
ACCUMULATOR (FOR PPC CIRCUIT).....252
BYPASS VALVE.....253
QUICK COUPLER SOLENOID VALVE.....256
ECSS VALVE.....257
ACCUMULATOR (FOR ECSS).....259
700 WORK EQUIPMENT.....262
WORK EQUIPMENT LINKAGE.....263
BUCKET.....267
BUCKET POSITIONER AND BOOM KICK-OUT.....271
WORK EQUIPMENT CYLINDER.....284
800 CAB AND ITS ATTACHMENTS.....288
CAB.....290
AIR CONDITIONER.....291
910 ELECTRICAL SYSTEM, PART 1.....304
MACHINE MONITOR SYSTEM.....305
MACHINE MONITOR.....309
920 ELECTRICAL SYSTEM, PART 2.....332
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM).....333
HST CONTROLLER.....349
ECSS SYSTEM.....351
KOMTRAX SYSTEM.....353
ENGINE STARTING CIRCUIT.....355
ENGINE STOPPING CIRCUIT.....357
PREHEATING CIRCUIT.....358
ENGINE OUTPUT DERATING FUNCTION.....359
AUTOMATIC WARM-UP FUNCTION.....359
PARKING BRAKE CIRCUIT.....360
COUPLER PLUNGER CONTROL SYSTEM.....363
MULTI-FUNCTION KNOB.....364
MAX. TRACTION SWITCH.....365
SENSOR.....366
20 STANDARD VALUE TABLE.....0
100 STANDARD SERVICE VALUE TABLE.....374
STANDARD SERVICE VALUE TABLE FOR ENGINE.....375
STANDARD SERVICE VALUE TABLE FOR CHASSIS.....376
30 TESTING AND ADJUSTING.....0
110 TESTING AND ADJUSTING, PART 1.....384
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....385
Sketches of special tools.....390
Measuring engine speed.....391
Measuring exhaust gas color.....393
ADJUSTING VALVE CLEARANCE.....394
MEASURING COMPRESSION PRESSURE.....396
MEASURING BLOW-BY PRESSURE.....399
TESTING ENGINE OIL PRESSURE.....400
MEASURING INTAKE AIR (BOOST) PRESSURE.....401
HANDLING FUEL SYSTEM EQUIPMENT.....403
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM.....403
MEASURING FUEL PRESSURE.....404
MEASURING FUEL RETURN RATE AND LEAKAGE.....406
BLEEDING AIR FROM FUEL CIRCUIT.....410
Checking leakage in fuel system.....411
Handling cylinder cut-out mode operation.....412
Handling no-injection cranking operation.....412
HANDLING CONTROLLER VOLTAGE CIRCUIT.....413
CHECK OF MUFFLER AND MUFFLER STACK FOR LOOSENESS AND DAMAGE.....413
CHECK OF MUFFLER FUNCTION.....414
CHECK OF INSTALLED CONDITION OF CYLINDER HEAD AND MANIFOLDS.....414
CHECK OF ENGINE PIPING FOR DAMAGE AND LOOSENESS.....415
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.....415
REPLACING ALTERNATOR BELT.....416
120 TESTING AND ADJUSTING, PART 2.....418
CHECKING OPERATING FORCE OF ACCELERATOR PEDAL.....420
CHECKING DIRECTIONAL LEVER.....421
TESTING AND ADJUSTING HST OIL PRESSURE.....422
TESTING CLUTCH CONTROL PRESSURE.....427
TESTING AND ADJUSTING STEERING WHEEL.....428
TESTING AND ADJUSTING STEERING OIL PRESSURE.....430
BLEEDING AIR FROM STEERING CIRCUIT.....432
TESTING HYDRAULIC FAN.....433
MEASURING BRAKE PEDAL.....435
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.....436
MEASURING BRAKE PERFORMANCE.....437
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE.....438
TESTING WHEEL BRAKE OIL PRESSURE.....440
TESTING WEAR OF BRAKE DISC.....443
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT.....444
RELEASING RESIDUAL PRESSURE IN BRAKE ACCUMULATOR CIRCUIT.....445
TESTING PARKING BRAKE PERFORMANCE.....446
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE.....447
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.....448
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.....449
TESTING WORK EQUIPMENT PPC OIL PRESSURE.....450
BLEEDING AIR FROM HYDRAULIC CIRCUIT.....452
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....453
TESTING AND ADJUSTING BUCKET POSITIONER.....454
TESTING AND ADJUSTING OF BOOM KICK-OUT SWITCH.....456
CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP.....457
PROCEDURE FOR TESTING DIODES.....458
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM.....460
STARTING KOMTRAX TERMINAL OPERATIONS.....464
INDICATOR LAMPS OF KOMTRAX TERMINAL.....468
130 TESTING AND ADJUSTING, PART 3.....472
ADJUSTING MACHINE MONITOR.....473
ADJUSTING REPLACED, REASSEMBLED OR ADDED SENSOR, CONTROLLER, ETC. WITH MACHINE MONITOR.....474
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).....476
PM CLINIC INSPECTION CHART.....530
40 TROUBLESHOOTING.....0
100 FAILURE CODE TABLE AND FUSE LOCATIONS.....534
FAILURE CODES TABLE.....535
FUSE LOCATIONS.....541
200 General information on troubleshooting.....546
Points to remember when troubleshooting.....547
Sequence of events in troubleshooting.....548
Testing before troubleshooting.....549
Classification and procedures of troubleshooting.....550
Information contained in troubleshooting table.....553
Connection table for connector pin numbers.....555
T- branch box and T- branch adapter table.....591
310 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1.....596
FAILURE CODE [2G40GZ] BRAKE: OIL PRESSURE REDUCTION.....597
FAILURE CODE [6091NX] HST FILTER: CLOGGING.....599
FAILURE CODE [989FN1] TRAVEL SPEED: OVERRUN ALARM.....600
FAILURE CODE [AB00L6] ALTERNATOR R SYSTEM: HOT SHORT.....601
FAILURE CODE [AB00MA] ALTERNATOR R SYSTEM: GROUND FAULT/DISCONNECTION CHARGE/LOW CHARGE VOLTAGE.....603
FAILURE CODE [B@BAZG] ENGINE: OIL PRESSURE REDUCTION.....605
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT.....606
FAILURE CODE [B@BCZK] ENGINE: LOW COOLANT LEVEL.....607
FAILURE CODE [B@C6NS] FRONT BRAKE: HIGH OIL TEMPERATURE.....609
FAILURE CODE [B@CRNS] HST: HIGH OIL TEMPERATURE.....610
320 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2.....612
FAILURE CODE [CA111] ABNORMALITY IN ENGINE CONTROLLER.....614
FAILURE CODE [CA115] ENGINE NE OR BKUP SPEED SENSOR ERROR.....615
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR HIGH ERROR.....617
FAILURE CODE [CA123] CHARGE PRESSURE SENSOR LOW ERROR.....619
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR.....621
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR.....623
FAILURE CODE [CA144] COOLANT SENSOR HIGH ERROR.....625
FAILURE CODE [CA145] COOLANT SENSOR LOW ERROR.....627
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR HIGH ERROR.....629
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR LOW ERROR.....631
FAILURE CODE [CA155] DERATING OF SPEED BY ABNORMALLY HIGH CHARGE TEMPERATURE.....633
FAILURE CODE [CA187] SENSOR POWER SUPPLY 2 LOW ERROR.....635
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR HIGH ERROR.....637
FAILURE CODE [CA222] ATMOSPHERIC SENSOR LOW ERROR.....639
FAILURE CODE [CA227] SENSOR POWER SUPPLY 2 HIGH ERROR.....641
FAILURE CODE [CA234] ENGINE OVERSPEED.....642
FAILURE CODE [CA238] NE SPEED SENSOR POWER SUPPLY ERROR.....643
FAILURE CODE [CA271] IMV (IMA) SHORT CIRCUIT.....644
FAILURE CODE [CA272] IMV (IMA) DISCONNECTION.....645
FAILURE CODE [CA322] INJECTOR #1 OPEN/SHORT ERROR.....647
FAILURE CODE [CA324] INJECTOR #3 OPEN/SHORT ERROR.....649
FAILURE CODE [CA331] INJECTOR #2 OPEN/SHORT ERROR.....651
FAILURE CODE [CA332] INJECTOR #4 OPEN/SHORT ERROR.....653
FAILURE CODE [CA342] CALIBRATION CODE INCONSISTENCY.....655
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR.....657
FAILURE CODE [CA352] SENSOR POWER SUPPLY 1 LOW ERROR.....659
FAILURE CODE [CA386] SENSOR POWER SUPPLY 1 HIGH ERROR.....661
330 Troubleshooting by failure code (Display of code), Part 3.....664
Failure code [CA428] Abnormally high level in water sensor.....667
Failure code [CA429] Abnormally low level in water sensor.....669
Failure code [CA431] Idle validation switch error.....671
Failure code [CA432] Idle validation action error.....675
Failure code [CA435] Engine oil pressure switch error.....679
Failure code [CA441] Battery voltage low error.....680
Failure code [CA442] Battery voltage high error.....683
Failure code [CA449] Common rail pressure high error 2.....685
Failure code [CA451] Common rail pressure sensor high error.....687
Failure code [CA452] Common rail pressure sensor low error.....689
Failure code [CA488] Derating of torque by abnormally high charge temperature.....691
Failure code [CA553] Common rail pressure high error 1.....692
Failure code [CA559] Supply pump pressure very low error.....693
Failure code [CA689] Engine Ne speed sensor error.....695
Failure code [CA731] Engine Bkup speed sensor phase error.....697
Failure code [CA757] All continuous data lost error.....698
Failure code [CA778] Engine Bkup speed sensor error.....701
Failure code [CA1633] KOMNET datalink timeout error.....703
Failure code [CA2185] Throttle sensor supply voltage high error.....705
Failure code [CA2186] Throttle sensor power supply low error.....707
Failure code [CA2249] Supply pump pressure very low error 2.....709
Failure code [CA2311] Abnormality in IMV (IMA) solenoid.....711
Failure code [CA2555] Intake heater relay disconnection error.....713
Failure code [CA2556] Intake heater relay short circuit error.....715
340 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4.....718
FAILURE CODE [D160KY] BACKUP ALARM/LAMP RELAY 1 CIRCUIT: HOT SHORT.....719
FAILURE CODE [D192KY] ECSS SOLENOID RELAY: HOT SHORT.....721
FAILURE CODE [D1B0KA] HST SAFETY RELAY: DISCONNECTION.....723
FAILURE CODE [D1B0KB] HST SAFETY RELAY: GROUND FAULT.....725
FAILURE CODE [D1B0KY] HST SAFETY RELAY: HOT SHORT.....727
FAILURE CODE [D5ZHL6] IGN C SYSTEM: GROUND FAULT/DISCONNECTION.....729
FAILURE CODE [DAF3KK] UNSW POWER SUPPLY: GROUND FAULT/DISCONNECTION.....731
FAILURE CODE [DAFRKR] MACHINE MONITOR CAN-NET SIGNAL: DISCONNECTION.....733
FAILURE CODE [DAJ0KK] HST CONTROLLER POWER SUPPLY: LOW VOLTAGE.....737
FAILURE CODE [DAJ0KT] HST CONTROLLER MEMORY (EEPROM): ABNORMALITY.....739
FAILURE CODE [DAJ1L4] HST CONTROLLER MAIN POWER LINE: DISCONNECTION/GROUND FAULT.....741
FAILURE CODE [DAJ1L6] HST CONTROLLER MAIN POWER LINE: HOT SHORT.....743
FAILURE CODE [DAJ2KK] CONTROLLER SOLENOID POWER SUPPLY: LOW VOLTAGE.....745
FAILURE CODE [DAJ2L3] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: HOT SHORT IN WIRING HARNESS.....747
FAILURE CODE [DAJ2L4] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: DISCONNECTION/GROUND FAULT.....749
FAILURE CODE [DAJ5KX] SENSOR 5V POWER SUPPLY: OUT OF OUTPUT RANGE.....751
FAILURE CODE [DAJ9KQ] HST CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS.....753
FAILURE CODE [DAJRKR] HST CONTROLLER CAN-NET SIGNAL: DISCONNECTION.....754
FAILURE CODE [DAJRMA] HST CONTROLLER: DISAGREEMENT IN OPTION SELECTION.....760
350 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5.....762
FAILURE CODE [DB2RKR] ENGINE CONTROLLER CAN-NET: DISCONNECTION IN SIGNAL LINE.....763
FAILURE CODE [DD1NL4] FAN AUTOMATIC REVERSE SWITCH SIGNAL: ABNORMALITY.....769
FAILURE CODE [DD1NLD] FAN REVERSE SWITCH SIGNAL: ABNORMALITY.....771
FAILURE CODE [DDB6KA] PARKING BRAKE SWITCH A: DISCONNECTION/HOT SHORT.....773
FAILURE CODE [DDB6KB] PARKING BRAKE SWITCH B: GROUND FAULT.....775
FAILURE CODE [DDB6KZ] PARKING BRAKE SWITCH (BOTTOM SWITCH) OR PARKING BRAKE REMINDER SWITCH (INTERMEDIATE SWITCH): TROUBLE.....777
FAILURE CODE [DDB6L0] PARKING BRAKE SWITCH A: GROUND FAULT.....779
FAILURE CODE [DDB6L4] PARKING BRAKE SWITCH B: DISCONNECTION/HOT SHORT.....781
FAILURE CODE [DDD7KX] TRAVEL SPEED CONTROL DIAL SIGNAL: DISCONNECTION/GROUND FAULT.....783
FAILURE CODE [DDD7KY] TRAVEL SPEED CONTROL DIAL SIGNAL: HOT SHORT.....785