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KOMATSU WA200-7 WHEEL LOADER SHOP MANUAL SEN06503-14 – PDF DOWNLOAD
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Description
KOMATSU WA200-7 WHEEL LOADER SHOP MANUAL SEN06503-14 – PDF DOWNLOAD
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KOMATSU WA200-7 WHEEL LOADER SHOP MANUAL SEN06503-14 – PDF DOWNLOAD
Language : English
Pages : 1590
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA200-7 WHEEL LOADER SHOP MANUAL SEN06503-14 – PDF DOWNLOAD
Cover............................................................................................................................... 1 00 Index and foreword............................................................................................................... 3 Index and foreword.............................................................................................................. 4 Index....................................................................................................................... 4 Important safety notice..................................................................................................... 18 How to read the shop manual................................................................................................. 25 Explanation of terms for maintenance standard............................................................................... 27 Handling equipment of fuel system devices................................................................................... 29 Handling of intake system parts............................................................................................. 30 Handling of hydraulic equipment............................................................................................. 31 Method of disconnecting and connecting of push-pull type coupler............................................................ 33 Handling of electrical equipment............................................................................................ 36 How to read electric wire code.............................................................................................. 44 Precautions when performing operation....................................................................................... 47 Practical use of KOMTRAX.................................................................................................... 52 Standard tightening torque table............................................................................................ 53 List of Abbreviation........................................................................................................ 59 Conversion table............................................................................................................ 63 01 Specifications................................................................................................................... 69 Specifications.................................................................................................................. 72 Specification dimension drawing............................................................................................. 72 Specifications.............................................................................................................. 74 Weight table................................................................................................................ 82 Table of fuel, coolant, and lubricants...................................................................................... 86 10 Structure and function........................................................................................................... 89 Engine and cooling system....................................................................................................... 92 VFT......................................................................................................................... 92 EGR system piping drawing................................................................................................... 96 EGR system circuit diagram.................................................................................................. 98 EGR valve................................................................................................................... 100 EGR cooler.................................................................................................................. 102 KCCV layout drawing......................................................................................................... 104 KCCV ventilator............................................................................................................. 107 KDOC muffler................................................................................................................ 111 Damper...................................................................................................................... 113 Cooling system.............................................................................................................. 114 Cooling system hydraulic piping diagram..................................................................................... 115 Cooling fan motor........................................................................................................... 116 Power train..................................................................................................................... 125 Power train................................................................................................................. 125 Power train system diagram.................................................................................................. 126 Drive shaft................................................................................................................. 128 HST hydraulic piping diagram................................................................................................ 129 HST pump.................................................................................................................... 130 HST motor................................................................................................................... 138 Transfer.................................................................................................................... 144 Clutch solenoid valve....................................................................................................... 150 Axle........................................................................................................................ 151 Differential................................................................................................................ 153 Torque proportioning differential........................................................................................... 156 Limited slip differential................................................................................................... 157 Final drive................................................................................................................. 160 Steering system................................................................................................................. 163 Steering piping diagram..................................................................................................... 163 Orbitrol valve.............................................................................................................. 164 Steering column............................................................................................................. 172 Priority valve.............................................................................................................. 173 Emergency steering valve.................................................................................................... 176 Brake system.................................................................................................................... 179 Brake piping diagram........................................................................................................ 179 Brake valve................................................................................................................. 180 Charge valve................................................................................................................ 184 Accumulator (for brake)..................................................................................................... 188 Slack adjuster.............................................................................................................. 189 Brake....................................................................................................................... 191 Parking brake control....................................................................................................... 194 Parking brake............................................................................................................... 195 Parking brake cylinder...................................................................................................... 196 Parking brake solenoid valve................................................................................................ 197 Inching valve............................................................................................................... 199 Undercarriage and frame......................................................................................................... 200 Axle mount and center hinge pin............................................................................................. 200 Hydraulic system................................................................................................................ 202 Hydraulic component layout.................................................................................................. 202 Work equipment control lever linkage........................................................................................ 204 Hydraulic tank.............................................................................................................. 205 Accumulator (for PPC circuit)............................................................................................... 207 Work equipment control valve................................................................................................ 208 PPC valve................................................................................................................... 221 Attachment EPC valve........................................................................................................ 227 Work equipment lock solenoid valve.......................................................................................... 228 ECSS valve.................................................................................................................. 229 Accumulator (for ECSS)...................................................................................................... 231 2-way restrictor valve...................................................................................................... 232 Cushion valve............................................................................................................... 233 Accumulator (for oil cooler circuit)........................................................................................ 234 Quadruple gear pump......................................................................................................... 235 Quick coupler solenoid valve................................................................................................ 236 Work equipment.................................................................................................................. 237 Work equipment linkage...................................................................................................... 237 Bucket...................................................................................................................... 239 Bucket positioner and boom kick-out......................................................................................... 240 Cab and its attachments......................................................................................................... 246 Cab......................................................................................................................... 246 Electrical system............................................................................................................... 247 Machine monitor system...................................................................................................... 247 Machine monitor............................................................................................................. 252 Electrical system (HST controller system)................................................................................... 274 System component parts...................................................................................................... 290 HST controller.............................................................................................................. 296 ECSS........................................................................................................................ 300 KOMTRAX system.............................................................................................................. 302 Engine starting circuit..................................................................................................... 305 Engine stopping circuit..................................................................................................... 307 Preheating system........................................................................................................... 308 Automatic preheating system................................................................................................. 309 Manual preheating system.................................................................................................... 309 Engine output limit function................................................................................................ 310 Automatic warm-up function.................................................................................................. 310 Parking brake control system................................................................................................ 311 Multi-function mono-lever................................................................................................... 315 Sensor...................................................................................................................... 317 20 Standard value table............................................................................................................. 333 Standard value table............................................................................................................ 335 Standard value table for engine............................................................................................. 335 Standard value table for machine............................................................................................ 337 30 Testing and adjusting............................................................................................................ 345 Related information on testing and adjusting.................................................................................... 348 Tools for testing and adjusting............................................................................................. 348 Engine and cooling system....................................................................................................... 351 Testing and adjusting engine speed.......................................................................................... 351 Testing exhaust gas temperature............................................................................................. 353 Testing exhaust gas color................................................................................................... 354 Testing and adjusting valve clearance....................................................................................... 356 Testing compression pressure................................................................................................ 358 Testing blowby pressure..................................................................................................... 361 Testing engine oil pressure................................................................................................. 362 Testing boost pressure...................................................................................................... 363 Handling equipment of fuel system devices................................................................................... 365 Releasing remaining pressure from fuel system............................................................................... 365 Visual check inside of EGRvalve............................................................................................. 366 Clean inside of EGR valve................................................................................................... 367 Testing fuel pressure....................................................................................................... 370 Testing fuel discharge, return and leakage.................................................................................. 375 Bleeding air from fuel system............................................................................................... 380 Testing fuel circuit for leakage............................................................................................ 382 Handling cylinder cutout mode operation..................................................................................... 383 Handling no-injection cranking operation.................................................................................... 383 Testing KDPF and muffler stack for looseness and damage..................................................................... 384 Testing KDOC function....................................................................................................... 384 Testing installed condition of cylinder heads and manifolds................................................................. 385 Testing engine piping for damage and looseness.............................................................................. 385 Testing and adjusting air conditioner compressor belt tension............................................................... 386 Testing and replacing alternator belt....................................................................................... 387 Testing and replacing auto-tensioner........................................................................................ 389 Power train..................................................................................................................... 391 Testing oil leakage from axle final drive................................................................................... 391 Testing drive shaft for looseness, backlash, and damage..................................................................... 392 Testing accelerator pedal................................................................................................... 393 Testing and adjusting HST oil pressure...................................................................................... 395 Testing transfer clutch control pressure.................................................................................... 400 Steering system................................................................................................................. 401 Testing directional lever................................................................................................... 401 Testing and adjusting steering wheel........................................................................................ 402 Testing work equipment control lever........................................................................................ 404 Testing and adjusting steering circuit oil pressure......................................................................... 405 Bleeding air from steering circuit.......................................................................................... 407 Brake system.................................................................................................................... 408 Testing brake pedal......................................................................................................... 408 Testing and adjusting brake pedal and linkage............................................................................... 409 Testing braking performance................................................................................................. 410 Testing and adjusting accumulator charge pressure........................................................................... 411 Testing wheel brake oil pressure............................................................................................ 413 Testing lowering of wheel brake pressure.................................................................................... 414 Testing wear of wheel brake disc............................................................................................ 417 Bleeding air from wheel brake circuit....................................................................................... 418 Releasing remaining pressure in brake accumulator circuit................................................................... 419 Testing parking brake performance........................................................................................... 420 Testing parking brake release pressure...................................................................................... 421 Method of releasing parking brake manually.................................................................................. 422 Hydraulic system................................................................................................................ 423 Testing and adjusting cooling fan speed..................................................................................... 423 Testing cooling fan pump circuit oil pressure............................................................................... 424 Testing work equipment PPC oil pressure..................................................................................... 425 Testing and adjusting work equipment oil pressure........................................................................... 426 Bleeding air from each part................................................................................................. 427 Releasing remaining pressure in hydraulic circuit........................................................................... 428 Work equipment.................................................................................................................. 429 Testing and adjusting bucket positioner..................................................................................... 429 Testing and adjusting boom kick-out switch.................................................................................. 430 Checking the proximity switch working pilot lamp............................................................................ 431 Electrical system............................................................................................................... 433 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor...................................... 433 Special functions of machine monitor........................................................................................ 435 KOMTRAX terminal start-up procedure......................................................................................... 489 Lamp indication of KOMTRAX terminal......................................................................................... 492 Handling voltage circuit of controller...................................................................................... 496 Test diodes................................................................................................................. 497 Pm Clinic....................................................................................................................... 498 Pm Clinic service........................................................................................................... 498 40 Troubleshooting.................................................................................................................. 501 Related information on troubleshooting.......................................................................................... 509 Points to remember when performing troubleshooting.......................................................................... 509 How to proceed in troubleshooting........................................................................................... 511 Checks before troubleshooting............................................................................................... 513 Check procedure before troubleshooting...................................................................................... 515 Preparation for troubleshooting of electrical system........................................................................ 533 Classification and procedures of troubleshooting............................................................................ 538 Symptom and troubleshooting No.............................................................................................. 542 Information described in troubleshooting table.............................................................................. 544 Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system................................... 546 Connector list and layout................................................................................................... 548 Connection table of connector by No. of pins................................................................................ 561 T-box and T-adapter list.................................................................................................... 598 Fuse location table......................................................................................................... 602 Failure code list........................................................................................................... 605 Troubleshooting by failure code (Display of code)............................................................................... 613 Failure code [2F00MB] Malfunction of Parking Brake.......................................................................... 613 Failure code [2G42ZG] Accumulator Oil Pressure Low (Front).................................................................. 615 Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear)................................................................... 617 Failure code [6091NX] HST Filter Clogging................................................................................... 619 Failure code [7RHYKA] Open Circuit of Fan Motor EPC Solenoid Output......................................................... 621 Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output......................................................... 623 Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output............................................................ 625 Failure code [989FN1] Travel Speed Overrun Alarm............................................................................ 627 Failure code [AB00L6] Discharge of Alternator R Terminal.................................................................... 628 Failure code [AB00MA] Ground Fault or Open Circuit of Battery Relay Status Signal Line, or Insufficient Battery Charging.... 630 Failure code [B@BAZG] Engine Oil Pressure Low............................................................................... 632 Failure code [B@BCNS] Engine Water Overheat................................................................................. 633 Failure code [B@BCZK] Engine Coolant Level Low.............................................................................. 634 Failure code [B@C6NS] Front Brake Oil Temperature Overheat (This Alarm)..................................................... 636 Failure code [B@CRNS] HST Oil Temperature Overheat.......................................................................... 637 Failure code [CA115] Eng Ne and Bkup Speed Sens Error....................................................................... 638 Failure code [CA122] Charge Air Pressure Sensor High Error.................................................................. 639 Failure code [CA123] Charge Air Pressure Sensor Low Error................................................................... 641 Failure code [CA131] Throttle Sensor High Error............................................................................. 643 Failure code [CA132] Throttle Sensor Low Error.............................................................................. 645 Failure code [CA144] Coolant Temperature Sensor High Error.................................................................. 647 Failure code [CA145] Coolant Temperature Sensor Low Error................................................................... 649 Failure code [CA153] Charge Air Temperature Sensor High Error............................................................... 651 Failure code [CA154] Chg Air Temp Sensor Low Error.......................................................................... 653 Failure code [CA187] Sensor 2 Supply Voltage Low Error...................................................................... 655 Failure code [CA221] Ambient Pressure Sensor High Error..................................................................... 657 Failure code [CA222] Ambient Pressure Sensor Low Error...................................................................... 659 Failure code [CA227] Sensor 2 Supply Voltage High Error..................................................................... 661 Failure code [CA234] Engine Overspeed....................................................................................... 662 Failure code [CA238] Ne Speed Sensor Supply Volt Error...................................................................... 663 Failure code [CA239] Ne Speed Sens Supply Volt High Error................................................................... 664 Failure code [CA271] IMV/PCV1 Short Error................................................................................... 665 Failure code [CA272] IMV/PCV1 Open Error.................................................................................... 667 Failure code [CA295] Ambient Press Sens In Range Error...................................................................... 669 Failure code [CA322] Injector #1 (L#1) Open/Short Error..................................................................... 670 Failure code [CA324] Injector #3 (L#3) Open/Short Error..................................................................... 672 Failure code [CA331] Injector #2 (L#2) Open/Short Error..................................................................... 674 Failure code [CA332] Injector #4 (L#4) Open/Short Error..................................................................... 676 Failure code [CA343] Engine Controller Internal Failure..................................................................... 678 Failure code [CA351] Injectors Drive Circuit Error.......................................................................... 679 Failure code [CA352] Sensor 1 Supply Voltage Low Error...................................................................... 680 Failure code [CA356] Mass Air Flow Sensor High Error........................................................................ 682 Failure code [CA357] Mass Air Flow Sensor Low Error......................................................................... 684 Failure code [CA386] Sensor 1 Supply Voltage High Error..................................................................... 686 Failure code [CA428] Water in Fuel Sensor High Error........................................................................ 687 Failure code [CA429] Water in Fuel Sensor Low Error......................................................................... 689 Failure code [CA431] Idle Validation Sw Error............................................................................... 691 Failure code [CA432] Idle Validation Process Error.......................................................................... 694 Failure code [CA435] Engine Oil Pressure Sw Error........................................................................... 696 Failure code [CA441] Battery Voltage Low Error.............................................................................. 697 Failure code [CA442] Battery Voltage High Error............................................................................. 699 Failure code [CA449] Rail Press Very High Error............................................................................. 700 Failure code [CA451] Common Rail Pressure Sensor High Error................................................................. 701 Failure code [CA452] Common Rail Pressure Sensor Low Error.................................................................. 703 Failure code [CA466] KVGT Motor Driver Position Error....................................................................... 705 Failure code [CA488] Chg Air Temp High Torque Derate........................................................................ 707 Failure code [CA515] Rail Pressure Sensor Sup Volt High Error............................................................... 708 Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error................................................................ 710 Failure code [CA553] Common Rail Pressure High Error 1...................................................................... 712 Failure code [CA555] Crankcase Press High Error 1........................................................................... 713 Failure code [CA556] Crankcase Press High Error 2........................................................................... 714 Failure code [CA559] Rail Press Low Error 1................................................................................. 715 Failure code [CA689] Engine Ne Speed Sensor Error........................................................................... 718 Failure code [CA691] Intake Air Temp Sens High Error........................................................................ 720 Failure code [CA692] Intake Air Temp Sens Low Error......................................................................... 722 Failure code [CA697] ECM Internal Temperature Sensor High Error............................................................. 724 Failure code [CA698] EMC Internal Temperature Sensor Low Error.............................................................. 725 Failure code [CA731] Engine Bkup Speed Sensor Phase Error................................................................... 726 Failure code [CA778] Engine Bkup Speed Sensor Error......................................................................... 728 Failure code [CA1117] Persistent Data Lost Error............................................................................ 733 Failure code [CA1695] Sensor 5 Supply Voltage High Error.................................................................... 734 Failure code [CA1696] Sensor 5 Supply Voltage Low Error..................................................................... 735 Failure code [CA1843] Crankcase Press Sens High Error....................................................................... 736 Failure code [CA1844] Crankcase Press Sens Low Error........................................................................ 738 Failure code [CA1896] EGR Valve Stuck Error................................................................................. 740 Failure code [CA1942] Crankcase Press Sens In-Range Error................................................................... 743 Failure code [CA1961] EGR Motor Driver IC Over Temp Error................................................................... 744 Failure code [CA2185] Throttle Sensor Supply Voltage High Error............................................................. 745 Failure code [CA2186] Throttle Sensor Supply Voltage Low Error.............................................................. 747 Failure code [CA2249] Rail Press Low Error 2................................................................................ 749 Failure code [CA2272] EGR Valve Position Sensor Low Error................................................................... 750 Failure code [CA2311] IMV Solenoid Error.................................................................................... 752 Failure code [CA2349] EGR Valve Solenoid Open Circuit Error................................................................. 753 Failure code [CA2353] EGR Valve Solenoid Short Circuit Error................................................................ 755 Failure code [CA2357] EGR Valve Servo Error................................................................................. 757 Failure code [CA2373] Exhaust Manifold Pressure Sensor High Error........................................................... 758 Failure code [CA2374] Exhaust Manifold Pressure Sensor Low Error............................................................ 760 Failure code [CA2375] EGR Orifice Temperature Sensor High Error............................................................. 762 Failure code [CA2376] EGR Orifice Temperature Sensor Low Error.............................................................. 764 Failure code [CA2554] Exhaust Manifold Pressure Sensor In-Range Error....................................................... 766 Failure code [CA2555] Grid Heater Relay Voltage Low Error................................................................... 767 Failure code [CA2556] Grid Heater Relay Voltage High Error.................................................................. 769 Failure code [CA2961] EGR Orifice Temperature High Error 1.................................................................. 771 Failure code [CA2973] Charge Air Pressure Sensor In-Range Error............................................................. 772 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error.............................................................. 773 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error............................................................... 775 Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error................................................................. 777 Failure code [CA3741] Common Rail Pressure Valve Trip Error................................................................. 779 Failure code [CA3918] KVGT Stuck Error...................................................................................... 780 Failure code [CA3919] KVGT Motor Driver IC Over Temperature Error........................................................... 781 Failure code [CA3921] KVGT Servo Error 2.................................................................................... 782 Failure code [CA3922] KVGT Motor Driver Open Error.......................................................................... 783 Failure code [CA3923] KVGT Motor Driver Short Error......................................................................... 785 Failure code [D110L4] Disconnection or Short to Ground of Battery Relay Signal Line......................................... 787 Failure code [D160KA] Disconnection of Backup Lamp Relay Output............................................................. 789 Failure code [D160KB] Ground Fault of Backup Lamp Relay Output.............................................................. 791 Failure code [D160KY] Hot Short of Backup Lamp Relay Output................................................................. 793 Failure code [D191KA] Disconnection of Neutral Output Relay................................................................. 795 Failure code [D191KB] Ground Fault of Neutral Output Relay.................................................................. 797 Failure code [D191KY] Hot Short of Neutral Output Relay..................................................................... 799 Failure code [D192KA] Disconnection of ECSS Solenoid Relay.................................................................. 801 Failure code [D192KB] Ground Fault of ECSS Solenoid Relay................................................................... 803 Failure code [D192KY] Hot Short of ECSS Solenoid Relay...................................................................... 805 Failure code [D1B0KA] Disconnection of HST Safety Relay..................................................................... 807 Failure code [D1B0KB] Ground Fault of HST Safety Relay...................................................................... 809 Failure code [D1B0KY] Hot Short of HST Safety Relay......................................................................... 811 Failure code [D1B0MC] Malfunction of HST Safety Relay....................................................................... 813 Failure code [D1E6KA] Disconnection of Parking Brake Relay.................................................................. 814 Failure code [D1E6KB] Ground Fault of Parking Brake Relay................................................................... 816 Failure code [D1E6KY] Hot Short of Parking Brake Relay...................................................................... 818 Failure code [D5ZHKA] Failure of Key SW C Signal............................................................................ 820 Failure code [D5ZHKB] Key SW C Signal Hot Short Circuit..................................................................... 822 Failure code [D5ZHL6] Disconnection of Key SW C............................................................................. 824 Failure code [DAF3KK] Controller Power Source Low (MON)..................................................................... 826 Failure code [DAF5KP] 5 V Sensor Power Supply: Ground Fault................................................................. 828 Failure code [DAF6KP] 24 V Sensor Power Supply: Ground Fault................................................................ 830 Failure code [DAFRKR] Machine Monitor CAN2 Communication Error (Machine Monitor)............................................ 832 Failure code [DAJ0KK] Controller Power Source Low (HST)..................................................................... 833 Failure code [DAJ0KT] Abnormality of Non-volatile Memory (HST).............................................................. 836 Failure code [DAJ0MC] HST Controller Malfunction............................................................................ 837 Failure code [DAJ1KA] Disconnection of Key SW ACC (HST)..................................................................... 838 Failure code [DAJ2KK] Solenoid Power Source Low (HST)....................................................................... 840 Failure code [DAJ4KB] Ground Fault of Solenoid Self-Holding Relay (HST)..................................................... 843 Failure code [DAJ4KZ] Failure of Solenoid Self-Holding Relay (HST).......................................................... 845 Failure code [DAJ5KX] Failure of 5 V Power Source 0 (HST)................................................................... 847 Failure code [DAJ6KX] Failure of 5 V Power Source 1 (HST)................................................................... 849 Failure code [DAJ9KQ] Inconsistency of Model Selection (HST)................................................................ 851 Failure code [DAJLKA] Operating Lamp Open Circuit (HST)..................................................................... 852 Failure code [DAJLKB] Operating Lamp Short Circuit (HST).................................................................... 854 Failure code [DAJQKR] CAN2 Disconnection (HST).............................................................................. 856 Failure code [DAJRMA] Inconsistency of Option Selection (HST)............................................................... 857 Failure code [DB2QKR] CAN2 Disconnection (Engine Controller)................................................................ 858 Failure code [DB2RKR] CAN1 Disconnection (Engine Controller)................................................................ 862 Failure code [DBE6KX] 24V Output Power Supply System Failure................................................................ 865 Failure code [DD1NL4] Fan Auto Reverse Switch Signal Error.................................................................. 867 Failure code [DD1NLD] Fan Reverse Switch Signal: Abnormal................................................................... 869 Failure code [DDB6L4] Parking Brake Signal Malfunction...................................................................... 871 Failure code [DDD7KA] Failure of Variable Speed Control..................................................................... 873 Failure code [DDD7KY] Hot Short of Variable Speed Control................................................................... 875 Failure code [DDE5MA] Disconnection of Steering Oil Pressure Switch (Emergency Steering Control Switch)..................... 877 Failure code [DDK3KA] FNR SW Input Signal Disconnection..................................................................... 879 Failure code [DDK3KB] FNR SW Input Signal Short Circuit..................................................................... 881 Failure code [DDK6KA] FNR Lever Input Signal Disconnection.................................................................. 883 Failure code [DDK6KY] FNR Lever Input Signal Disconnection (Hot Short)...................................................... 885 Failure code [DDNRLD] Ground Fault of Work Equipment Lock Switch............................................................ 887 Failure code [DDS5L6] Low Steering Oil Pressure (Emergency Steering Control)................................................ 889 Failure code [DF10KA] Disconnection of Speed Range Input Switch............................................................. 891 Failure code [DF10KB] Disconnection of Speed Range Selector Switch (Hot Short).............................................. 896 Failure code [DGH1KX] HST Oil Temperature Sensor Short to Ground............................................................ 901 Failure code [DGR2KB] Ground Fault of Brake Oil Temperature Sensor.......................................................... 903 Failure code [DGR2KZ] Failure of Brake Oil Temperature Sensor............................................................... 905 Failure code [DHH1KX] Failure of HST Oil Pressure Sensor.................................................................... 907 Failure code [DHH1KY] Hot Short of HST Oil Pressure Sensor.................................................................. 909 Failure code [DHPCKX] Failure of Boom Pressure Sensor (Bottom).............................................................. 911 Failure code [DHPDKX] Failure of Boom Pressure Sensor (Head)................................................................ 913 Failure code [DHTCL6] HST Oil Filter Clogging Detection Failure............................................................. 915 Failure code [DJF1KA] Disconnection or Hot Short Circuit of Fuel Level Sensor............................................... 917 Failure code [DK5DKA] Failure of 3rd Lever Potentiometer Sensor (Main)...................................................... 919 Failure code [DK5DKY] Hot Short of 3rd Lever Potentiometer Sensor (Main).................................................... 922 Failure code [DK5DL8] 3rd Lever Potentiometer Sensor (Main & Sub) Disagree.................................................. 924 Failure code [DK5EKA] Failure of 3rd Lever Potentiometer Sensor (Sub)....................................................... 927 Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub)..................................................... 930 Failure code [DKA0KX] Failure of Boom Angle Sensor.......................................................................... 932 Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor................................................................... 934 Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor.............................................................. 936 Failure code [DLT3KX] Vehicle Speed Sensor Circuit Failure (B).............................................................. 937 Failure code [DLT4KX] Vehicle Speed Sensor Circuit Failure (A).............................................................. 939 Failure code [DLT4L0] Vehicle Speed Sensor Failure (A & B).................................................................. 941 Failure code [DLT4LC] Vehicle Speed Sensor Failure (A or B)................................................................. 944 Failure code [DT22KB] Ground Fault of Work Equip. Lock Indicator............................................................ 946 Failure code [DV00KY] Hot Short of Alarm Buzzer............................................................................. 948 Failure code [DW26KA] Open Circuit of Motor 2 Solenoid...................................................................... 950 Failure code [DW26KB] Ground Fault of Motor 2 Solenoid...................................................................... 952 Failure code [DW26KY] Hot Short of Motor 2 Solenoid......................................................................... 954 Failure code [DW44KA] Open Circuit of Directional Pressure Selection Solenoid............................................... 956 Failure code [DW44KB] Ground Fault of Directional Pressure Selection Solenoid............................................... 958 Failure code [DW44KY] Hot Short of Directional Pressure Selection Solenoid.................................................. 960 Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid................................................................ 962 Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid................................................................. 964 Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid.................................................................... 966 Failure code [DX19KA] Disconnection of Motor 1 Solenoid..................................................................... 968 Failure code [DX19KB] Ground Fault of Motor 1 Solenoid...................................................................... 971 Failure code [DX19KY] Hot Short of Motor 1 Solenoid......................................................................... 973 Failure code [DX20KA] Disconnection of Clutch EPC Solenoid.................................................................. 975 Failure code [DX20KB] Ground Fault of Clutch EPC Solenoid................................................................... 978 Failure code [DX20KY] Hot Short of Clutch EPC Solenoid...................................................................... 980 Failure code [DXH7KA] Disconnection of Reverse Solenoid..................................................................... 982 Failure code [DXH7KB] Ground Fault of Reverse Solenoid...................................................................... 984 Failure code [DXH7KY] Hot Short of Reverse Solenoid......................................................................... 986 Failure code [DXH8KA] Disconnection of Forward Solenoid..................................................................... 987 Failure code [DXH8KB] Ground Fault of Forward Solenoid...................................................................... 989 Failure code [DXH8KY] Hot Short of Forward Solenoid......................................................................... 991 Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT)............................................................... 992 Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)................................................................ 994 Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT)................................................................... 996 Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET)............................................................... 997 Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET)................................................................ 999 Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET)...................................................................1001 Failure code [H2K0KA] Failure of Quick Coupler Lock Signal..................................................................1002 Failure code [H2K0KY] Hot Short of Quick Coupler Lock Signal................................................................1005 Failure code [J141N1] Steering Pump Over Run................................................................................1007 Failure code [LA00L3] Failure of Fan Reverse................................................................................1008 Failure code [M100N1] HST Pump Over Run.....................................................................................1009 Failure code [M400N1] HST Motor 1 Over Run..................................................................................1010 Troubleshooting of electrical system (E-mode)...................................................................................1011 E-1 Engine does not start...................................................................................................1011 E-2 Manual preheating system does not work..................................................................................1016 E-3 Automatic preheating system does not work...............................................................................1019 E-4 While preheating is working, preheating monitor does not light up.......................................................1021 E-5 When starting switch is turned to ON position, nothing is displayed on machine monitor..................................1023 E-6 Travel speed is slow....................................................................................................1026 E-7 ECSS does not operate...................................................................................................1028 E-8 ECSS remains being operated.............................................................................................1031 E-9 Boom kick-out does not work or is not reset.............................................................................1034 E-10 Bucket positioner does not work or is not reset........................................................................1037 E-11 Boom FLOAT holding does not work or is not reset.......................................................................1040 E-12 Directional selection does not work normally...........................................................................1043 E-13 Fan does not rotate in reverse.........................................................................................1054 E-14 Fan remains in reverse rotation mode...................................................................................1057 E-15 Wipers do not operate..................................................................................................1059 E-16 Window washer does not operate.........................................................................................1064 E-17 Headlamp, clearance lamp, tail lamp or license-plate lamp does not light up or does not go out.........................1067 E-18 Working lamp does not light up or does not go out......................................................................1076 E-19 Turn signal and hazard lamp do not light up or do not go out...........................................................1081 E-20 Stop lamp does not light up or remains lighting up.....................................................................1088 E-21 Backup lamp does not light up or remains lighting up...................................................................1091 E-22 Backup alarm does not sound or does not stop sounding..................................................................1094 E-23 Horn does not sound or does not stop sounding..........................................................................1096 E-24 Alarm buzzer does not sound or does not stop sounding..................................................................1099 E-25 KOMTRAX system does not operate normally...............................................................................1101 E-26 Fuel gauge does not indicate correct level.............................................................................1103 E-27 Seat belt caution lamp indication is incorrect.........................................................................1105 Troubleshooting for hydraulic and mechanical system (H-mode)....................................................................1107 Information described in troubleshooting table (H-mode).....................................................................1107 System chart of hydraulic and mechanical systems............................................................................1108 Failure mode and cause table................................................................................................1110 H-1 Machine travels neither forward nor in reverse..........................................................................1116 H-2 Machine does not travel forward (normally travels in reverse)...........................................................1118 H-3 Machine does not travel in reverse (normally travels forward)...........................................................1119 H-4 Both forward and reverse travel speeds are low..........................................................................1120 H-5 Forward travel speed is low (normal when traveling in reverse)..........................................................1122 H-6 Reverse travel speed is low (normal when traveling forward).............................................................1123 H-7 Machine lacks power when traveling both forward and in reverse..........................................................1124 H-8 Machine lacks power when traveling forward (normal when traveling in reverse)...........................................1126 H-9 Machine lacks power when traveling in reverse (normal when traveling forward)...........................................1127 H-10 Engine stalls during travel or engine speed drops significantly........................................................1128 H-11 Machine does not turn..................................................................................................1129 H-12 Steering wheel is heavy to turn........................................................................................1131 H-13 Machine sways or large shocks are made while machine turns.............................................................1132 H-14 Machine turns to either side unintentionally during traveling..........................................................1133 H-15 Brake does not work or it is weak......................................................................................1134 H-16 Brake is not released or drags.........................................................................................1135 H-17 Parking brake does not work or it is weak..............................................................................1136 H-18 Parking brake is not released or drags.................................................................................1137 H-19 Boom does not rise.....................................................................................................1138 H-20 Boom moves slow or lacks lifting force.................................................................................1139 H-21 Boom rising speed lowers at certain height.............................................................................1140 H-22 Lift cylinder cannot hold down bucket (bucket rises off ground)........................................................1141 H-23 Hydraulic drift of boom is large.......................................................................................1142 H-24 Boom wobbles during operation..........................................................................................1146 H-25 Bucket does not tilt back..............................................................................................1147 H-26 Bucket moves slow or lacks tilting back force..........................................................................1148 H-27 Bucket speed lowers in tilt-back motion................................................................................1149 H-28 Bucket cylinder cannot hold down bucket (bucket rises off ground)......................................................1150 H-29 Hydraulic drift of bucket is large.....................................................................................1151 H-30 Loaded bucket wobbles during travel (with work equipment valve at "HOLD")..............................................1152 H-31 Boom and bucket control levers do not move smoothly and are heavy to move..............................................1153 H-32 Engine speed lowers remarkably or engine stalls while work equipment is operated.......................................1154 H-33 Large shock is made when work equipment starts and stops...............................................................1155 H-34 When certain work equipment is relieved hydraulically, other work equipment moves......................................1156 H-35 ECSS does not operate and machine pitches and bounds...................................................................1157 H-36 Fan speed is abnormal (too high or low, or fan does not rotate)........................................................1158 H-37 Unusual noise is heard from around fan.................................................................................1160 Troubleshooting of engine (S-mode)..............................................................................................1161 Information mentioned in troubleshooting table (S mode).....................................................................1161 S-1 Engine does not crank when starting switch is turned to START position..................................................1162 S-2 Engine cranks but no exhaust smoke comes out............................................................................1163 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)..........................1164 S-4 Engine startability is poor.............................................................................................1165 S-5 Engine does not pick up smoothly........................................................................................1167 S-6 Engine stops during operation...........................................................................................1169 S-7 Engine runs rough or is unstable........................................................................................1170 S-8 Engine lacks power......................................................................................................1171 S-9 Exhaust smoke is black..................................................................................................1173 S-10 Engine oil consumption is excessive....................................................................................1175 S-11 Oil becomes contaminated quickly.......................................................................................1176 S-12 Fuel consumption is excessive..........................................................................................1177 S-13 Oil is in coolant (or coolant spurts or coolant level goes down).......................................................1178 S-14 Oil pressure drops.....................................................................................................1179 S-15 Fuel mixes into engine oil.............................................................................................1180 S-16 Water mixes into engine oil (milky)....................................................................................1181 S-17 Coolant temperature rises too high (overheating).......................................................................1182 S-18 Unusual noise is heard.................................................................................................1183 S-19 Vibration is excessive.................................................................................................1184 S-20 Air cannot be bled from fuel circuit...................................................................................1185 50 Disassembly and assembly.........................................................................................................1187 General information on disassembly and assembly.................................................................................1190 How to read this manual.....................................................................................................1190 Coating materials list......................................................................................................1192 Special tool list...........................................................................................................1196 Sketches of special tools...................................................................................................1200 Engine and cooling system.......................................................................................................1210 Removal and installation of fuel supply pump assembly.......................................................................1210 Removal and installation of fuel injector assembly..........................................................................1214 Removal and installation of engine hood assembly............................................................................1222 Removal and installation of cylinder head assembly..........................................................................1225 Removal and installation of radiator assembly...............................................................................1237 Removal and installation of air aftercooler assembly........................................................................1240 Removal and installation of hydraulic oil cooler assembly...................................................................1242 Removal and installation of engine assembly.................................................................................1244 Removal and installation of belt for alternator and air conditioner compressor..............................................1250 Removal and installation of engine front oil seal assembly..................................................................1252 Removal and installation of engine rear oil seal assembly...................................................................1256 Removal and installation of cooling fan and fan motor assembly..............................................................1260 Removal and installation of fuel tank assembly..............................................................................1263 Removal and installation of KCCV ventilator assembly........................................................................1265 Removal and installation of KDOC muffler....................................................................................1266 Removal and installation of EGR cooler assembly.............................................................................1268 Removal and installation of EGR valve assembly..............................................................................1270 Power train.....................................................................................................................1272 Removal and installation of transfer assembly...............................................................................1272 Disassembly and assembly of transfer assembly...............................................................................1276 Removal and installation of parking brake assembly..........................................................................1299 Removal and installation of parking brake cylinder assembly.................................................................1301 Disassembly and assembly of parking brake assembly..........................................................................1302 Removal and installation of front axle assembly.............................................................................1308 Removal and installation of rear axle assembly..............................................................................1310 Disassembly and assembly of axle housing assembly...........................................................................1313 Disassembly and assembly of differential assembly...........................................................................1322 Undercarriage and frame.........................................................................................................1348 Removal and installation of center hinge pin................................................................................1348 Removal and installation of counterweight assembly..........................................................................1357 Hydraulic system................................................................................................................1360 Removal and installation of HST pump and quadruple type gear pump assembly..................................................1360 Removal and installation of HST motor 1 assembly............................................................................1364 Removal and installation of HST motor 2 assembly............................................................................1366 Removal and installation of work equipment control valve assembly...........................................................1369 Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly...............................1371 Removal and installation of hydraulic tank assembly.........................................................................1373 Disassembly and assembly of hydraulic cylinder assembly.....................................................................1375 Work equipment..................................................................................................................1379 Removal and installation of work equipment assembly.........................................................................1379 Cab and its attachments.........................................................................................................1385 Removal and installation of operator's cab and floor frame assembly.........................................................1385 Removal and installation of operator's cab glass (adhered glass)............................................................1390 Disassembly and assembly of operator's seat.................................................................................1398 Removal and installation of air conditioner unit assembly...................................................................1408 Removal and installation of air conditioner compressor assembly.............................................................1414 Electrical system...............................................................................................................1416 Removal and installation of machine monitor.................................................................................1416 Removal and installation of engine controller assembly......................................................................1418 Removal and installation of HST controller assembly.........................................................................1420 Removal and installation of KOMTRAX terminal assembly.......................................................................1421 60 Maintenance standard.............................................................................................................1423 Engine and cooling system.......................................................................................................1425 Engine mount and transfer mount.............................................................................................1425 Damper......................................................................................................................1426 Cooling system..............................................................................................................1427 Cooling fan motor...........................................................................................................1428 Power train.....................................................................................................................1430 Drive shaft.................................................................................................................1430 Transfer....................................................................................................................1431 Axle........................................................................................................................1439 Differential................................................................................................................1441 Limited slip differential...................................................................................................1445 Final drive.................................................................................................................1447 Steering system.................................................................................................................1450 Orbitrol valve..............................................................................................................1450 Steering cylinder...........................................................................................................1451 Steering column.............................................................................................................1454 Priority valve..............................................................................................................1455 Emergency steering valve....................................................................................................1456 Brake system....................................................................................................................1458 Charge valve................................................................................................................1458 Slack adjuster..............................................................................................................1460 Brake.......................................................................................................................1461 Parking brake...............................................................................................................1463 Undercarriage and frame.........................................................................................................1464 Axle mount and center hinge pin.............................................................................................1464 Hydraulic system................................................................................................................1468 Hydraulic tank..............................................................................................................1468 Work equipment control valve................................................................................................1469 PPC valve...................................................................................................................1475 ECSS valve..................................................................................................................1478 Quadruple gear pump.........................................................................................................1479 Work equipment..................................................................................................................1481 Work equipment linkage......................................................................................................1481 Bucket......................................................................................................................1483 Bucket positioner and boom kick-out.........................................................................................1484 Work equipment cylinder.....................................................................................................1485 80 Appendix.........................................................................................................................1487 Air conditioner.................................................................................................................1489 Precautions for refrigerant.................................................................................................1489 Air conditioner component...................................................................................................1490 Configuration and function of refrigeration cycle...........................................................................1492 Outline of refrigeration cycle..............................................................................................1493 Air conditioner unit........................................................................................................1495 Functions of main components in air conditioner unit........................................................................1496 Blower and intake unit......................................................................................................1497 Compressor..................................................................................................................1498 Condenser...................................................................................................................1499 Receiver drier..............................................................................................................1500 Air conditioner control panel...............................................................................................1501 Procedure for troubleshooting...............................................................................................1502 Circuit diagram and arrangement of connector pins...........................................................................1504 System diagram..............................................................................................................1506 Details of air conditioner unit.............................................................................................1508 Parts and connectors layout.................................................................................................1509 Inspection by self-diagnosis function (displays diagnosis on the control panel).............................................1511 Testing temperature control system..........................................................................................1512 Testing FRESH/RECIRC air changeover.........................................................................................1513 Testing evaporator temperature sensor.......................................................................................1515 Testing relays..............................................................................................................1516 Troubleshooting chart 1.....................................................................................................1517 Troubleshooting chart 2.....................................................................................................1519 Information described in troubleshooting table..............................................................................1522 Troubleshooting for power supply system (Air conditioner does not operate)..................................................1523 Troubleshooting for compressor and refrigerant system (Air is not cooled)...................................................1527 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)..........................................1530 Troubleshooting for temperature control.....................................................................................1533 Troubleshooting for FRESH/RECIRC air changeover.............................................................................1536 Connection of service tool..................................................................................................1538 Troubleshooting by gauge pressure...........................................................................................1540 Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit.....................................1543 Handling of compressor oil..................................................................................................1545 90 Diagrams and drawings............................................................................................................1549 Hydraulic diagrams and drawings.................................................................................................1551 Symbols used in hydraulic circuit diagrams..................................................................................1551 Hydraulic circuit diagram...................................................................................................1553 Electrical diagrams and drawings................................................................................................1555 Symbols used in electric circuit diagrams...................................................................................1555 Electrical circuit diagram..................................................................................................1559 Index...............................................................................................................................1581
DESCRIPTION:
KOMATSU WA200-7 WHEEL LOADER SHOP MANUAL SEN06503-14 – PDF DOWNLOAD
General precautions
- Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
- Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
- When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc. - When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
- Only qualified workers must perform the work and operation which require license or qualification.
- Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
- If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
- Before starting work, warm up your body thoroughly to start work under good condition.
- Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 30/12/24
