Komatsu WA200-6, WA200PZ-6 70001 & Up SEN05282-00 (Preview)
COVER
00 Index and foreword
– 100 Index
— Composition of shop manual
— Table of contents
– 200 Foreword and general information
— Safety notice
— How to read the shop manual
— Explanation of terms for maintenance standard
— Handling of electric equipment and hydraulic component
— Handling of connectors newly used for engines
— How to read electric wire code
— Precautions when carrying out operation
— Method of disassembling and connecting push-pull type coupler
— Standard tightening torque table
— Conversion table
01 Specification
– 100 Specification and technical data
— Specification dimension drawing
— Specifications
— Weight table
— Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
– 100 Engine and cooling system
— Engine mount and transfer mount
— Damper
— Cooling system
— Cooling system hydraulic piping diagram
— Cooling fan motor
– 200 Power train
— Power train
— Power train system diagram
— Drive shaft
— HST hydraulic piping diagram
— HST pump
— HST motor
— Transfer
— Clutch solenoid valve
— Axle
— Differential
— Torque proportioning differential
— Limited slip differential
— Final drive
– 300 Steering system
— Steering piping diagram
— Steering column
— Priority valve
— Orbit-roll valve
— 2-way restrictor valve
— Cushion valve
— Steering cylinder
— Emergency steering piping diagram
— Emergency steering valve
— Steering relief valve
– 400 Brake system
— Brake piping diagram
— Charge valve
— Brake valve
— Inching valve
— Accumulator (for brake)
— Slack adjuster
— Brake
— Parking brake control
— Parking brake
– 500 Undercarriage and frame
— Axle mount and center hinge pin
— Tires
– 600 Hydraulic system
— Work equipment hydraulic piping diagram
— Work equipment control lever linkage
— Hydraulic tank
— 4-gear pump
— Work equipment control valve
— PPC valve
— Lock valve
— Accumulator (for PPC circuit)
— Bypass valve
— Quick coupler solenoid valve
— ECSS valve
— Accumulator (for ECSS)
– 700 Work equipment
— Work equipment linkage
— Bucket
— Bucket positioner and boom kick-out
— Work equipment cylinder
– 800 Cab and its attachments
— Cab
— Air conditioner
– 901 Electrical system, Part 1
— Machine monitor system
— Machine monitor
– 902 Electrical system, Part 2
— Electrical system (HST controller system)
— HST controller
— ECSS system
— KOMTRAX system
— Engine starting circuit
— Engine stopping circuit
— Preheating circuit
— Engine output derating function
— Automatic warm-up function
— Parking brake circuit
— Coupler plunger control system
— Max. traction switch
— Multi-function knob
— Sensor
20 Standard value table
– 100 Standard service value table
— Standard service value table for engine
— Standard service value table for chassis
30 Testing and adjusting
– 101 Testing and adjusting, Part 1
— Tools for testing, adjusting, and troubleshooting
— Sketches of special tools
— Measuring engine speed
— Measuring exhaust gas color
— Adjusting valve clearance
— Measuring compression pressure
— Measuring blow-by pressure
— Testing engine oil pressure
— Measuring intake air (boost) pressure
— Handling fuel system equipment
— Releasing residual pressure in fuel system
— Measuring fuel pressure
— Measuring fuel return rate and leakage
— Bleeding air from fuel circuit
— Checking leakage in fuel system
— Handling cylinder cut-out mode operation
— Handling no-injection cranking operation
— Handling controller voltage circuit
— Check of muffler and muffler stack for looseness and damage
— Check of muffler function
— Check of installed condition of cylinder head and manifolds
— Check of engine piping for damage and looseness
— Testing and adjusting air conditioner compressor belt tension
— Replacing alternator belt
– 102 Testing and adjusting, Part 2
— Checking operating force of accelerator pedal
— Checking directional lever
— Testing and adjusting HST oil pressure
— Testing clutch control pressure
— Testing and adjusting steering wheel
— Testing and adjusting steering oil pressure
— Bleeding air from steering circuit
— Testing hydraulic fan
— Measuring brake pedal
— Testing and adjusting brake pedal linkage
— Measuring brake performance
— Testing and adjusting accumulator charge pressure
— Testing wheel brake oil pressure
— Testing wear of brake disc
— Bleeding air from wheel brake circuit
— Releasing residual pressure in brake accumulator circuit
— Testing parking brake performance
— Testing and adjusting parking brake control cable
— Measuring and adjusting work equipment control lever
— Testing and adjusting work equipment hydraulic pressure
— Testing work equipment PPC oil pressure
— Bleeding air from hydraulic circuit
— Releasing remaining pressure in hydraulic circuit
— Testing and adjusting bucket positioner
— Testing and adjusting boom kick-out switch
— Checking proximity switch operation pilot lamp
— Procedure for testing diodes
— Preparation work for troubleshooting for electric system
— Starting KOMTRAX terminal operations
— Indicator lamps of KOMTRAX terminal
– 103 Testing and adjusting, Part 3
— Adjusting machine monitor
— Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
— Special functions of machine monitor (EMMS)
— Pm clinic inspection chart
40 Troubleshooting
– 100 Failure code table and fuse locations
— Failure codes table
— Fuse locations
– 200 General information on troubleshooting
— Points to remember when troubleshooting
— Sequence of events in troubleshooting
— Testing before troubleshooting
— Classification and procedures of troubleshooting
— Information contained in troubleshooting table
— Connection table for connector pin numbers
— T- branch box and T- branch adapter table
– 301 Troubleshooting by failure code (Display of code), Part 1
— Failure code [2G40ZG] Brake: Oil pressure reduction
— Failure code [6091NX] HST filter: Clogging
— Failure code [989FN1] Travel speed: Overrun alarm
— Failure code [AB00L6] Alternator R system: Hot short
— Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage
— Failure code [B@BAZG] Engine: Oil pressure reduction
— Failure code [B@BCNS] Engine: Overheat
— Failure code [B@BCZK] Engine: Low coolant level
— Failure code [B@C6NS] Front brake: High oil temperature
— Failure code [B@CRNS] HST: High oil temperature
– 302 Troubleshooting by failure code (Display of code), Part 2
— Failure code [CA111] Abnormality in engine controller
— Failure code [CA115] Engine Ne or Bkup speed sensor error
— Failure code [CA122] Charge pressure sensor high error
— Failure code [CA123] Charge pressure sensor low error
— Failure code [CA131] Throttle sensor high error
— Failure code [CA132] Throttle sensor low error
— Failure code [CA144] Coolant sensor high error
— Failure code [CA145] Coolant sensor low error
— Failure code [CA153] Charge temperature sensor high error
— Failure code [CA154] Charge temperature sensor low error
— Failure code [CA155] Derating of speed by abnormally high charge temperature
— Failure code [CA187] Sensor power supply 2 low error
— Failure code [CA221] Atmospheric pressure sensor high error
— Failure code [CA222] Atmospheric sensor low error
— Failure code [CA227] Sensor power supply 2 high error
— Failure code [CA234] Engine overspeed
— Failure code [CA238] Ne speed sensor power supply error
— Failure code [CA271] IMV (IMA) Short circuit
— Failure code [CA272] IMV (IMA) Disconnection
— Failure code [CA322] Injector #1 open/short error
— Failure code [CA324] Injector #3 open/short error
— Failure code [CA331] Injector #2 open/short error
— Failure code [CA332] Injector #4 open/short error
— Failure code [CA342] Calibration code inconsistency
— Failure code [CA351] Injectors drive circuit error
— Failure code [CA352] Sensor power supply 1 low error
— Failure code [CA386] Sensor power supply 1 high error
– 303 Troubleshooting by failure code (Display of code), Part 3
— Failure code [CA428] Abnormally high level in water sensor
— Failure code [CA429] Abnormally low level in water sensor
— Failure code [CA431] Idle validation switch error
— Failure code [CA432] Idle validation action error
— Failure code [CA435] Engine oil pressure switch error
— Failure code [CA441] Battery voltage low error
— Failure code [CA442] Battery voltage high error
— Failure code [CA449] Common rail pressure high error 2
— Failure code [CA451] Common rail pressure sensor high error
— Failure code [CA452] Common rail pressure sensor low error
— Failure code [CA488] Derating of torque by abnormally high charge temperature
— Failure code [CA553] Common rail pressure high error 1
— Failure code [CA559] Supply pump pressure very low error
— Failure code [CA689] Engine Ne speed sensor error
— Failure code [CA731] Engine Bkup speed sensor phase error
— Failure code [CA757] All continuous data lost error
— Failure code [CA778] Engine Bkup speed sensor error
— Failure code [CA1633] KOMNET datalink timeout error
— Failure code [CA2185] Throttle sensor supply voltage high error
— Failure code [CA2186] Throttle sensor power supply low error
— Failure code [CA2249] Supply pump pressure very low error 2
— Failure code [CA2311] Abnormality in IMV (IMA) solenoid
— Failure code [CA2555] Intake heater relay disconnection error
— Failure code [CA2556] Intake heater relay short circuit error
– 304 Troubleshooting by failure code (Display of code), Part 4
— Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short
— Failure code [D192KY] ECSS solenoid relay: Hot short
— Failure code [D1B0KA] HST safety relay: Disconnection
— Failure code [D1B0KB] HST safety relay: Ground fault
— Failure code [D1B0KY] HST safety relay: Hot short
— Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection
— Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection
— Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection
— Failure code [DAJ0KK] HST controller power supply: Low voltage
— Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality
— Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault
— Failure code [DAJ1L6] HST controller main power line: Hot short
— Failure code [DAJ2KK] Controller solenoid power supply: Low voltage
— Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness
— Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault
— Failure code [DAJ5KX] Sensor 5V power supply: Out of output range
— Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals
— Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection
— Failure code [DAJRMA] HST controller: Disagreement in option selection
– 305 Troubleshooting by failure code (Display of code), Part 5
— Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line
— Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality
— Failure code [DD1NLD] Fan reverse switch signal: Abnormality
— Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short
— Failure code [DDB6KB] Parking brake indicator signal: Ground fault
— Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble
— Failure code [DDB6L0] Parking brake reminder signal: Ground fault
— Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short
— Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault
— Failure code [DDD7KY] Travel speed control dial signal: Hot short
— Failure code [DDE5MA] Emergency steering operation switch: Disconnection
— Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
— Failure code [DDK6KY] FNR lever: Hot short
— Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)
– 306 Troubleshooting by failure code (Display of code), Part 6
— Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
— Failure code [DF10KB] Travel speed range selector switch: Hot short
— Failure code [DGH1KX] HST oil temperature sensor: Ground fault
— Failure code [DGR2KB] Brake oil temperature sensor: Ground fault
— Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short
— Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault
— Failure code [DHH1KY] HST oil pressure sensor: Hot short
— Failure code [DHTCL6] HST filter clogging sensor: Functional defect
— Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short
— Failure code [DLT3KX] Travel speed sensor B: Abnormality
— Failure code [DLT4KX] Travel speed sensor A: Abnormality
— Failure code [DLT4LC] Travel speed sensor A & B: Abnormality
— Failure code [DV00KY] Alarm buzzer: Hot short
— Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault
— Failure code [DW26KY] Motor 2 solenoid: Hot short
— Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short
— Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault
– 307 Troubleshooting by failure code (Display of code), Part 7
— Failure code [DX16KA] Fan EPC solenoid: Disconnection
— Failure code [DX16KB] Fan EPC solenoid: Ground fault
— Failure code [DX16KY] Fan EPC solenoid: Hot short
— Failure code [DX19KA] Motor 1 solenoid: Disconnection
— Failure code [DX19KB] Motor 1 solenoid: Ground fault
— Failure code [DX19KY] Motor 1 solenoid: Hot short
— Failure code [DX20KA] Clutch EPC solenoid: Disconnection
— Failure code [DX20KB] Clutch EPC solenoid: Ground fault
— Failure code [DX20KY] Clutch EPC solenoid: Hot short
— Failure code [DXH7KB] Reverse solenoid: Ground fault
— Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short
— Failure code [DXH8KB] Forward solenoid: Ground fault
— Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short
— Failure code [J141N1] Steering pump: Overrun alarm
— Failure code [M100N1] HST pump: Overrun alarm
— Failure code [M400N1] Motor 1: Overrun alarm
– 400 Troubleshooting of electrical system (E-mode)
— E-1 Engine does not start
— E-2 Preheater does not operate normally
— E-3 Travel speed is low or high
— E-4 ECSS does not operate
— E-5 ECSS keeps operating
— E-6 Defective boom kick-out function and cancellation
— E-7 Defective bucket positioner function and cancellation
— E-8 Defective lift arm FLOATING holding function and cancellation
— E-9 Travel direction selection system does not function
— E-10 Fan does not reverse
— E-11 Fan keeps rotating in reverse
— E-12 Wiper does not operate
— E-13 Windshield washer does not operate
— E-14 Headlamp, clearance lamp and tail lamp do not light up or go off
— E-15 Working lamp does not light up or go off
— E-16 Turn signal lamp and hazard lamp do not light up or go off
— E-17 Brake lamp does not light or it keeps lighting up
— E-18 Backup lamp does not light or it keeps lighting up
— E-19 Backup alarm does not sound or it keeps sounding
— E-20 Horn does not sound or it keeps sounding
— E-21 Alarm buzzer does not sound or it keeps sounding
— E-22 Air conditioner does not operate or stop
— E-23 The KOMTRAX system does not work properly
– 500 Troubleshooting of hydraulic and mechanical system (H-mode)
— Method of using troubleshooting chart
— Failure code and cause table
— H-1 The machine does not start
— H-2 The travel speed is slow
— H-3 The traction force is weak
— H-4 Engine stalls when traveling or engine speed drops excessively
— H-5 Speed range is not shifted
— H-6 The steering wheel does not turn
— H-7 The steering wheel is heavy
— H-8 Steering wheel shakes or jerks
— H-9 Machine deviates naturally to one side when traveling
— H-10 The brake does not work or does not work well
— H-11 The brake is not released or is dragged
— H-12 The lift arm does not rise or lower
— H-13 The lift arm moves slowly or the lift arm rising force is insufficient
— H-14 When rising, the lift arm comes to move slowly at specific height
— H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)
— H-16 Hydraulic drifts of the lift arm occur often
— H-17 The lift arm wobbles during operation
— H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily
— H-19 The bucket does not tilt back
— H-20 The bucket moves slowly or the tilting-back force is insufficient
— H-21 The bucket comes to operate slowly in the midst of tilting-back
— H-22 The bucket cylinder cannot hold down the bucket
— H-23 Hydraulic drifts of the bucket occur often
— H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)
— H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily
— H-26 The control levers of the lift arm and bucket do not move smoothly and heavy
— H-27 The ECSS does not operate and machine pitches and bounces
— H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
– 600 Troubleshooting of engine (S-mode)
— Method of using troubleshooting charts
— S-1 Starting performance is poor
— S-2 Engine does not start
— S-3 Engine does not pick up smoothly
— S-4 Engine stops during operations
— S-5 Engine does not rotate smoothly
— S-6 Engine lacks output (or lacks power)
— S-7 Exhaust smoke is black (incomplete combustion)
— S-8 Oil consumption is excessive (or exhaust smoke is blue)
— S-9 Oil becomes contaminated quickly
— S-10 Fuel consumption is excessive
— S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
— S-12 Oil pressure drops
— S-13 Oil level rises (Entry of coolant or fuel)
— S-14 Coolant temperature becomes too high (overheating)
— S-15 Abnormal noise is made
— S-16 Vibration is excessive
50 Disassembly and assembly
– 100 General information on disassembly and assembly
— How to read this manual
— Coating materials list
— Special tool list
— Sketches of special tools
– 200 Engine and cooling system
— Removal and installation of fuel supply pump assembly
— Removal and installation of fuel injector assembly
— Removal and installation of cylinder head assembly
— Removal and installation of engine hood assembly
— Removal and installation of radiator
— Removal and installation of air aftercooler
— Removal and installation of hydraulic oil cooler assembly
— Removal and installation of engine assembly
— Removal and installation of engine front oil seal assembly
— Removal and installation of engine rear oil seal assembly
— Removal and installation of cooling fan and fan motor assembly
— Removal and installation of fuel tank assembly
– 301 Power train, Part 1
— Disassembly and assembly of transfer assembly
— Removal and installation of parking brake assembly
— Disassembly and assembly of parking brake assembly
– 302 Power train, Part 2
— Removal and installation of front axle assembly
— Removal and installation of rear axle assembly
— Disassembly and assembly of axle housing assembly
— Disassembly and assembly of differential assembly
– 400 Undercarriage and frame
— Removal and installation of center hinge pin
— Removal and installation of counterweight assembly
– 500 Hydraulic system
— Removal and installation of HST pump and 4-gear pump assembly
— Disassembly and assembly of HST pump assembly
— Removal and installation of HST motor 1 assembly
— Removal and installation of HST motor 2 assembly
— Disassembly and assembly of HST motor assembly
— Removal and installation of work equipment control valve assembly
— Removal and installation of hydraulic tank
— Disassembly and assembly of hydraulic cylinder assembly
– 600 Work equipment
— Removal and installation of work equipment assembly
– 700 Cab and its attachments
— Removal and installation of operator’s cab and floor frame assembly
— Removal and installation of operator’s cab glass (Stuck glass)
— Removal and installation of air conditioner unit
– 800 Electrical system
— Removal and installation of monitor panel
— Removal and installation of engine controller assembly
— Removal and installation of HST controller assembly
— Removal and installation of KOMTRAX terminal assembly
90 Diagrams and drawings
– 100 Hydraulic diagrams and drawings
— Hydraulic circuit diagram
– 200 Electrical diagrams and drawings
— Common electrical circuit diagram
— Specific electrical circuit diagram
— Connector list and stereogram
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