Komatsu WA200-6 WA200PZ-6 Wheel Loader Shop Manual SEN05282-06 PDF

Cover 1
00 Index and foreword 0
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 0
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 0
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 158
Emergency steering valve 159
Steering relief valve 162
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 283
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 0
100 Standard service value table 377
Standard service value table for engine 378
Standard service value table for chassis 379
30 Testing and adjusting 0
101 Testing and adjusting, Part 1 387
Tools for testing, adjusting, and troubleshooting 388
Sketches of special tools 393
Measuring engine speed 394
Measuring exhaust gas color 396
Adjusting valve clearance 397
Measuring compression pressure 399
Measuring blow-by pressure 402
Testing engine oil pressure 403
Measuring intake air (boost) pressure 404
Handling fuel system equipment 406
Releasing residual pressure in fuel system 406
Measuring fuel pressure 407
Measuring fuel return rate and leakage 409
Bleeding air from fuel circuit 413
Checking leakage in fuel system 414
Handling cylinder cut-out mode operation 415
Handling no-injection cranking operation 415
Handling controller voltage circuit 416
Check of muffler and muffler stack for looseness and damage 416
Check of muffler function 417
Check of installed condition of cylinder head and manifolds 417
Check of engine piping for damage and looseness 418
Testing and adjusting air conditioner compressor belt tension 418
Replacing alternator belt 419
102 Testing and adjusting, Part 2 421
Checking operating force of accelerator pedal 423
Checking directional lever 424
Testing and adjusting HST oil pressure 425
Testing clutch control pressure 430
Testing and adjusting steering wheel 431
Testing and adjusting steering oil pressure 433
Bleeding air from steering circuit 435
Testing hydraulic fan 436
Measuring brake pedal 438
Testing and adjusting brake pedal linkage 439
Measuring brake performance 440
Testing and adjusting accumulator charge pressure 441
Testing wheel brake oil pressure 443
Testing wear of brake disc 446
Bleeding air from wheel brake circuit 447
Releasing residual pressure in brake accumulator circuit 448
Testing parking brake performance 449
Testing and adjusting parking brake control cable 450
Measuring and adjusting work equipment control lever 451
Testing and adjusting work equipment hydraulic pressure 452
Testing work equipment PPC oil pressure 453
Bleeding air from hydraulic circuit 455
Releasing remaining pressure in hydraulic circuit 456
Testing and adjusting bucket positioner 457
Testing and adjusting boom kick- out switch 459
Checking proximity switch operation pilot lamp 460
Procedure for testing diodes 461
Preparation work for troubleshooting for electric system 463
Starting KOMTRAX terminal operations 467
Indicator lamps of KOMTRAX terminal 471
Adjustment of rearview camera angle 474
103 Testing and adjusting, Part 3 477
Adjusting machine monitor 478
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor 479
Special functions of machine monitor (EMMS) 481
Pm clinic inspection chart 535
40 Troubleshooting 0
100 Failure code table and fuse locations 539
Failure codes table 540
Fuse locations 546
200 General information on troubleshooting 551
Points to remember when troubleshooting 552
Sequence of events in troubleshooting 553
Testing before troubleshooting 554
Classification and procedures of troubleshooting 555
Information contained in troubleshooting table 558
Connection table for connector pin numbers 560
T- branch box and T- branch adapter table 596
301 Troubleshooting by failure code (Display of code), Part 1 601
Failure code [2G40ZG] Brake: Oil pressure reduction 602
Failure code [6091NX] HST filter: Clogging 604
Failure code [989FN1] Travel speed: Overrun alarm 605
Failure code [AB00L6] Alternator R system: Hot short 606
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage 608
Failure code [B@BAZG] Engine: Oil pressure reduction 610
Failure code [B@BCNS] Engine: Overheat 611
Failure code [B@BCZK] Engine: Low coolant level 612
Failure code [B@C6NS] Front brake: High oil temperature 614
Failure code [B@CRNS] HST: High oil temperature 615
302 Troubleshooting by failure code (Display of code), Part 2 617
Failure code [CA111] Abnormality in engine controller 619
Failure code [CA115] Engine Ne or Bkup speed sensor error 620
Failure code [CA122] Charge pressure sensor high error 622
Failure code [CA123] Charge pressure sensor low error 624
Failure code [CA131] Throttle sensor high error 626
Failure code [CA132] Throttle sensor low error 628
Failure code [CA144] Coolant sensor high error 630
Failure code [CA145] Coolant sensor low error 632
Failure code [CA153] Charge temperature sensor high error 634
Failure code [CA154] Charge temperature sensor low error 636
Failure code [CA155] Derating of speed by abnormally high charge temperature 638
Failure code [CA187] Sensor power supply 2 low error 640
Failure code [CA221] Atmospheric pressure sensor high error 642
Failure code [CA222] Atmospheric sensor low error 644
Failure code [CA227] Sensor power supply 2 high error 646
Failure code [CA234] Engine overspeed 647
Failure code [CA238] Ne speed sensor power supply error 648
Failure code [CA271] IMV (IMA) Short circuit 649
Failure code [CA272] IMV (IMA) Disconnection 650
Failure code [CA322] Injector #1 open/short error 652
Failure code [CA324] Injector #3 open/short error 654
Failure code [CA331] Injector #2 open/short error 656
Failure code [CA332] Injector #4 open/short error 658
Failure code [CA342] Calibration code inconsistency 660
Failure code [CA351] Injectors drive circuit error 662
Failure code [CA352] Sensor power supply 1 low error 664
Failure code [CA386] Sensor power supply 1 high error 666
303 Troubleshooting by failure code (Display of code), Part 3 669
Failure code [CA428] Abnormally high level in water sensor 672
Failure code [CA429] Abnormally low level in water sensor 674
Failure code [CA431] Idle validation switch error 676
Failure code [CA432] Idle validation action error 680
Failure code [CA435] Engine oil pressure switch error 684
Failure code [CA441] Battery voltage low error 685
Failure code [CA442] Battery voltage high error 688
Failure code [CA449] Common rail pressure high error 2 690
Failure code [CA451] Common rail pressure sensor high error 692
Failure code [CA452] Common rail pressure sensor low error 694
Failure code [CA488] Derating of torque by abnormally high charge temperature 696
Failure code [CA553] Common rail pressure high error 1 697
Failure code [CA559] Supply pump pressure very low error 698
Failure code [CA689] Engine Ne speed sensor error 700
Failure code [CA731] Engine Bkup speed sensor phase error 702
Failure code [CA757] All continuous data lost error 703
Failure code [CA778] Engine Bkup speed sensor error 706
Failure code [CA1633] KOMNET datalink timeout error 708
Failure code [CA2185] Throttle sensor supply voltage high error 710
Failure code [CA2186] Throttle sensor power supply low error 712
Failure code [CA2249] Supply pump pressure very low error 2 714
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 716
Failure code [CA2555] Intake heater relay disconnection error 718
Failure code [CA2556] Intake heater relay short circuit error 720
304 Troubleshooting by failure code (Display of code), Part 4 723
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short 724
Failure code [D192KY] ECSS solenoid relay: Hot short 726
Failure code [D1B0KA] HST safety relay: Disconnection 728
Failure code [D1B0KB] HST safety relay: Ground fault 730
Failure code [D1B0KY] HST safety relay: Hot short 732
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection 734
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection 736
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection 738
Failure code [DAJ0KK] HST controller power supply: Low voltage 740
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality 742
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault 744
Failure code [DAJ1L6] HST controller main power line: Hot short 746
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage 748
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness 750
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault 752
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range 754
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals 756
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection 758
Failure code [DAJRMA] HST controller: Disagreement in option selection 763
305 Troubleshooting by failure code (Display of code), Part 5 765
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line 766
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality 772
Failure code [DD1NLD] Fan reverse switch signal: Abnormality 774
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short 776
Failure code [DDB6KB] Parking brake indicator signal: Ground fault 778
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble 780
Failure code [DDB6L0] Parking brake reminder signal: Ground fault 782
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short 784
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault 786
Failure code [DDD7KY] Travel speed control dial signal: Hot short 788
Failure code [DDE5MA] Emergency steering operation switch: Disconnection 790
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault 792
Failure code [DDK6KY] FNR lever: Hot short 796
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) 798
306 Troubleshooting by failure code (Display of code), Part 6 801
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault 802
Failure code [DF10KB] Travel speed range selector switch: Hot short 806
Failure code [DGH1KX] HST oil temperature sensor: Ground fault 808
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault 809
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short 810
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault 812
Failure code [DHH1KY] HST oil pressure sensor: Hot short 814
Failure code [DHTCL6] HST filter clogging sensor: Functional defect 816
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short 818
Failure code [DLT3KX] Travel speed sensor B: Abnormality 820
Failure code [DLT4KX] Travel speed sensor A: Abnormality 824
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality 826
Failure code [DV00KY] Alarm buzzer: Hot short 828
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault 830
Failure code [DW26KY] Motor 2 solenoid: Hot short 832
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short 834
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault 836
307 Troubleshooting by failure code (Display of code), Part 7 839
Failure code [DX16KA] Fan EPC solenoid: Disconnection 840
Failure code [DX16KB] Fan EPC solenoid: Ground fault 841
Failure code [DX16KY] Fan EPC solenoid: Hot short 842
Failure code [DX19KA] Motor 1 solenoid: Disconnection 844
Failure code [DX19KB] Motor 1 solenoid: Ground fault 846
Failure code [DX19KY] Motor 1 solenoid: Hot short 848
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 850
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 852
Failure code [DX20KY] Clutch EPC solenoid: Hot short 854
Failure code [DXH7KB] Reverse solenoid: Ground fault 856
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 858
Failure code [DXH8KB] Forward solenoid: Ground fault 860
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 862
Failure code [J141N1] Steering pump: Overrun alarm 864
Failure code [M100N1] HST pump: Overrun alarm 865
Failure code [M400N1] Motor 1: Overrun alarm 866
400 Troubleshooting of electrical system (E-mode) 869
E-1 Engine does not start 871
E-2 Preheater does not operate normally 878
E-3 Travel speed is low or high 882
E-4 ECSS does not operate 888
E-5 ECSS keeps operating 891
E-6 Defective boom kick-out function and cancellation 894
E-7 Defective bucket positioner function and cancellation 898
E-8 Defective lift arm FLOATING holding function and cancellation 902
E-9 Travel direction selection system does not function 906
E-10 Fan does not reverse 910
E-11 Fan keeps rotating in reverse 914
E-12 Wiper does not operate 916
E-13 Windshield washer does not operate 920
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off 924
E-15 Working lamp does not light up or go off 932
E-16 Turn signal lamp and hazard lamp do not light up or go off 937
E-17 Brake lamp does not light or it keeps lighting up 944
E-18 Backup lamp does not light or it keeps lighting up 946
E-19 Backup alarm does not sound or it keeps sounding 949
E-20 Horn does not sound or it keeps sounding 952
E-21 Alarm buzzer does not sound or it keeps sounding 954
E-22 Air conditioner does not operate or stop 957
E-23 The KOMTRAX system does not work properly 960
E-24 Rearview monitor does not light up or backlight flickers 962
E-25 Rearview monitor images are not displayed clearly 966
E-26 Rearview monitor brightness cannot be adjusted 970
E-27 Night lighting lamp of rearview monitor is abnormal 974
E-28 Reverse interlock function of rearview monitor does not operate properly 977
500 Troubleshooting of hydraulic and mechanical system (H-mode) 981
Method of using troubleshooting chart 983
Failure code and cause table 986
H-1 The machine does not start 988
H-2 The travel speed is slow 989
H-3 The traction force is weak 990
H-4 Engine stalls when traveling or engine speed drops excessively 991
H-5 Speed range is not shifted 992
H-6 The steering wheel does not turn 993
H-7 The steering wheel is heavy 994
H-8 Steering wheel shakes or jerks 995
H-9 Machine deviates naturally to one side when traveling 995
H-10 The brake does not work or does not work well 996
H-11 The brake is not released or is dragged 997
H-12 The lift arm does not rise or lower 998
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 999
H-14 When rising, the lift arm comes to move slowly at specific height 1000
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) 1000
H-16 Hydraulic drifts of the lift arm occur often 1000
H-17 The lift arm wobbles during operation 1000
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily 1001
H-19 The bucket does not tilt back 1002
H-20 The bucket moves slowly or the tilting-back force is insufficient 1003
H-21 The bucket comes to operate slowly in the midst of tilting-back 1004
H-22 The bucket cylinder cannot hold down the bucket 1004
H-23 Hydraulic drifts of the bucket occur often 1004
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”) 1004
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily 1005
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy 1005
H-27 The ECSS does not operate and machine pitches and bounces 1006
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 1007
600 Troubleshooting of engine (S-mode) 1009
Method of using troubleshooting charts 1010
S-1 Starting performance is poor 1014
S-2 Engine does not start 1015
S-3 Engine does not pick up smoothly 1018
S-4 Engine stops during operations 1019
S-5 Engine does not rotate smoothly 1020
S-6 Engine lacks output (or lacks power) 1021
S-7 Exhaust smoke is black (incomplete combustion) 1022
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1023
S-9 Oil becomes contaminated quickly 1024
S-10 Fuel consumption is excessive 1025
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1026
S-12 Oil pressure drops 1027
S-13 Oil level rises (Entry of coolant or fuel) 1028
S-14 Coolant temperature becomes too high (overheating) 1029
S-15 Abnormal noise is made 1030
S-16 Vibration is excessive 1031
50 Disassembly and assembly 0
100 General information on disassembly and assembly 1033
How to read this manual 1034
Coating materials list 1036
Special tool list 1039
Sketches of special tools 1043
200 Engine and cooling system 1053
Removal and installation of fuel supply pump assembly 1054
Removal and installation of fuel injector assembly 1058
Removal and installation of cylinder head assembly 1066
Removal and installation of engine hood assembly 1079
Removal and installation of radiator 1083
Removal and installation of air aftercooler 1086
Removal and installation of hydraulic oil cooler assembly 1088
Removal and installation of engine assembly 1090
Removal and installation of engine front oil seal assembly 1097
Removal and installation of engine rear oil seal assembly 1100
Removal and installation of cooling fan and fan motor assembly 1103
Removal and installation of fuel tank assembly 1106
301 Power train, Part 1 1109
Disassembly and assembly of transfer assembly 1110
Removal and installation of parking brake assembly 1130
Disassembly and assembly of parking brake assembly 1132
302 Power train, Part 2 1139
Removal and installation of front axle assembly 1140
Removal and installation of rear axle assembly 1142
Disassembly and assembly of axle housing assembly 1145
Disassembly and assembly of differential assembly 1153
400 Undercarriage and frame 1181
Removal and installation of center hinge pin 1182
Removal and installation of counterweight assembly 1191
500 Hydraulic system 1195
Removal and installation of HST pump and 4-gear pump assembly 1196
Disassembly and assembly of HST pump assembly 1200
Removal and installation of HST motor 1 assembly 1227
Removal and installation of HST motor 2 assembly 1229
Disassembly and assembly of HST motor assembly 1231
Removal and installation of work equipment control valve assembly 1247
Removal and installation of hydraulic tank 1249
Disassembly and assembly of hydraulic cylinder assembly 1251
600 Work equipment 1257
Removal and installation of work equipment assembly 1258
700 Cab and its attachments 1267
Removal and installation of operator’s cab and floor frame assembly 1268
Removal and installation of operator’s cab glass (Stuck glass) 1273
Removal and installation of air conditioner unit 1281
800 Electrical system 1289
Removal and installation of monitor panel 1290
Removal and installation of engine controller assembly 1292
Removal and installation of HST controller assembly 1294
Removal and installation of KOMTRAX terminal assembly 1295
90 Diagrams and drawings 0
100 Hydraulic diagrams and drawings 1297
Hydraulic circuit diagram 1299
200 Electrical diagrams and drawings 1303
Common electrical circuit diagram 1305
Specific electrical circuit diagram 1319
Connector list and stereogram 1320

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.