Shop Manual
WHEEL LOADER
SERIAL NUMBERS
WA200-
C10172 and up
WA200PZ
-
SEN05291-07
WHEEL LOADER WA200-6 WA200PZ-6 Machine model WA200-6 WA200PZ-6
Serial number
00 Index and foreword
00
100 Index Composition of shop manual .......................................................................................................................... 2 Table of contents ............................................................................................................................................. 4
WA200, 200PZ-6
00-100
1
SEN05291-07
100 Index Composition of shop manual
Composition of shop manual
1
The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.) Note 2: This shop manual can be supplied for each Form No. Note 3: To file this shop manual in the special binder for management, handle it as follows: Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below: File overview and other materials in sections in the order shown below and utilize them accordingly. Section Title
Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN05282
-07
00 Index and foreword .................................................................................................................... SEN05283-07 100 Index .................................................................................................................................. SEN05291-07 q 200 Foreword and general information ..................................................................................... SEN05292-00 01 Specification ............................................................................................................................... SEN05284-00 100 Specification and technical data......................................................................................... SEN05293-00 10 Structure, function and maintenance standard........................................................................... SEN05285-04 100 Engine and cooling system ................................................................................................ SEN05294-01 200 Power train......................................................................................................................... SEN05295-00 300 Steering system ................................................................................................................. SEN05296-01 q 400 Brake system ..................................................................................................................... SEN05297-00 500 Undercarriage and frame ................................................................................................... SEN05298-00 600 Hydraulic system................................................................................................................ SEN05299-00 700 Work equipment ................................................................................................................. SEN05300-01 q 800 Cab and its attachments .................................................................................................... SEN05301-00 901 Electrical system, Part 1 .................................................................................................... SEN05302-02 902 Electrical system, Part 2 .................................................................................................... SEN05303-00 20 Standard value table................................................................................................................... SEN05286-00 100 Standard service value table .............................................................................................. SEN05304-00 30 Testing and adjusting ................................................................................................................. SEN05287-05 101 Testing and adjusting, Part 1.............................................................................................. SEN05305-01 102 Testing and adjusting, Part 2.............................................................................................. SEN05306-03 103 Testing and adjusting, Part 3.............................................................................................. SEN05307-02 40 Troubleshooting.......................................................................................................................... SEN05288-01 100 Failure code table and fuse locations ................................................................................ SEN05308-01 200 General information on troubleshooting............................................................................. SEN05309-01 301 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN05310-00 302 Troubleshooting by failure code (Display of code), Part 2 ................................................. SEN05311-00 303 Troubleshooting by failure code (Display of code), Part 3 ................................................. SEN05312-00 304 Troubleshooting by failure code (Display of code), Part 4 ................................................. SEN05313-00 305 Troubleshooting by failure code (Display of code), Part 5 ................................................. SEN05314-00 00-100
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100 Index Composition of shop manual
SEN05291-07
306 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05315-00 307 Troubleshooting by failure code (Display of code), Part 7..................................................SEN05316-00 400 Troubleshooting of electrical system (E-mode) ..................................................................SEN05317-01 500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05318-00 600 Troubleshooting of engine (S-mode) ..................................................................................SEN05319-00 50 Disassembly and assembly ........................................................................................................SEN05289-03 100 General information on disassembly and assembly...........................................................SEN05320-00 200 Engine and cooling system ................................................................................................SEN05321-00 301 Power train, Part 1..............................................................................................................SEN05322-01 302 Power train, Part 2..............................................................................................................SEN05323-00 400 Undercarriage and frame ...................................................................................................SEN05324-01 500 Hydraulic system ................................................................................................................SEN05325-01 q 600 Work equipment .................................................................................................................SEN05326-00 700 Cab and its attachments.....................................................................................................SEN05327-00 800 Electrical system ................................................................................................................SEN05328-00 90 Diagrams and drawings ..............................................................................................................SEN05290-01 100 Hydraulic diagrams and drawings ......................................................................................SEN05329-00 200 Electrical diagrams and drawings.......................................................................................SEN05330-01
WA200, 200PZ-6
00-100
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SEN05291-07
Table of contents
100 Index Table of contents
1
00 Index and foreword 100 Index SEN05291-07 Composition of shop manual......................................................................................................................... 2 Table of contents ........................................................................................................................................... 4 200 Foreword and general information SEN05292-00 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code ...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 Specification 100 Specification and technical data SEN05293-00 Specification dimension drawing ................................................................................................................... 3 Specifications ................................................................................................................................................ 4 Weight table .................................................................................................................................................. 8 Table of fuel, coolant and lubricants .............................................................................................................. 10 10 Structure, function and maintenance standard 100 Engine and cooling system SEN05294-01 Engine mount and transfer mount................................................................................................................. 2 Damper ......................................................................................................................................................... 3 Cooling system.............................................................................................................................................. 4 Cooling system hydraulic piping diagram...................................................................................................... 5 Cooling fan motor.......................................................................................................................................... 7 200 Power train SEN05295-00 Power train .................................................................................................................................................... 3 Power train system diagram.......................................................................................................................... 4 Drive shaft ..................................................................................................................................................... 6 HST hydraulic piping diagram ....................................................................................................................... 7 HST pump ..................................................................................................................................................... 8 HST motor..................................................................................................................................................... 16 Transfer ......................................................................................................................................................... 22 Clutch solenoid valve .................................................................................................................................... 33 Axle ............................................................................................................................................................... 34 Differential ..................................................................................................................................................... 36 Torque proportioning differential.................................................................................................................... 41 Limited slip differential................................................................................................................................... 44 Final drive...................................................................................................................................................... 48 300 Steering system SEN05296-01 Steering piping diagram ................................................................................................................................ 3 Steering column ............................................................................................................................................ 4 Priority valve.................................................................................................................................................. 5 Orbit-roll valve ............................................................................................................................................... 8 2-way restrictor valve .................................................................................................................................... 16 Cushion valve................................................................................................................................................ 17 Steering cylinder............................................................................................................................................ 18 Emergency steering piping diagram.............................................................................................................. 21 Emergency steering valve............................................................................................................................. 22 Steering relief valve....................................................................................................................................... 25 00-100
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WA200, 200PZ-6
This is the sample of the manual Click on the download link for complete manual
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100 Index Table of contents
SEN05291-07
400 Brake system SEN05297-00 Brake piping diagram..................................................................................................................................... 3 Charge valve ................................................................................................................................................. 4 Brake valve.................................................................................................................................................... 8 Inching valve.................................................................................................................................................. 12 Accumulator (for brake) ................................................................................................................................. 13 Slack adjuster ................................................................................................................................................ 14 Brake ............................................................................................................................................................. 16 Parking brake control..................................................................................................................................... 21 Parking brake ................................................................................................................................................ 22 500 Undercarriage and frame SEN05298-00 Axle mount and center hinge pin ................................................................................................................... 2 Tires............................................................................................................................................................... 7 600 Hydraulic system SEN05299-00 Work equipment hydraulic piping diagram .................................................................................................... 2 Work equipment control lever linkage ........................................................................................................... 6 Hydraulic tank ................................................................................................................................................ 10 4-gear pump .................................................................................................................................................. 12 Work equipment control valve ....................................................................................................................... 15 PPC valve...................................................................................................................................................... 39 Lock valve...................................................................................................................................................... 54 Accumulator (for PPC circuit) ........................................................................................................................ 55 Bypass valve ................................................................................................................................................. 56 Quick coupler solenoid valve......................................................................................................................... 59 ECSS valve ................................................................................................................................................... 60 Accumulator (for ECSS) ................................................................................................................................ 62 700 Work equipment SEN05300-01 Work equipment linkage ................................................................................................................................ 2 Bucket............................................................................................................................................................ 6 Bucket positioner and boom kick-out............................................................................................................. 10 Work equipment cylinder ............................................................................................................................... 22 800 Cab and its attachments SEN05301-00 Cab ................................................................................................................................................................ 3 Air conditioner................................................................................................................................................ 4 901 Electrical system, Part 1 SEN05302-02 Machine monitor system................................................................................................................................ 2 Machine monitor ............................................................................................................................................ 6 Rearview monitor system .............................................................................................................................. 27 902 Electrical system, Part 2 SEN05303-00 Electrical system (HST controller system)..................................................................................................... 2 HST controller................................................................................................................................................ 18 ECSS system ................................................................................................................................................ 20 KOMTRAX system ........................................................................................................................................ 22 Engine starting circuit .................................................................................................................................... 24 Engine stopping circuit .................................................................................................................................. 26 Preheating circuit........................................................................................................................................... 27 Engine output derating function..................................................................................................................... 28 Automatic warm-up function .......................................................................................................................... 28 Parking brake circuit ...................................................................................................................................... 30 Coupler plunger control system..................................................................................................................... 32 Max. traction switch ....................................................................................................................................... 33 Multi-function knob ........................................................................................................................................ 34 Sensor ........................................................................................................................................................... 35 20 Standard value table 100 Standard service value table SEN05304-00 Standard service value table for engine ........................................................................................................ 2 WA200, 200PZ-6
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SEN05291-07
100 Index Table of contents
Standard service value table for chassis .......................................................................................................
3
30 Testing and adjusting 101 Testing and adjusting, Part 1 SEN05305-01 Tools for testing, adjusting, and troubleshooting ........................................................................................... 2 Sketches of special tools............................................................................................................................... 7 Measuring engine speed............................................................................................................................... 8 Measuring exhaust gas color ........................................................................................................................ 10 Adjusting valve clearance ............................................................................................................................. 11 Measuring compression pressure ................................................................................................................. 13 Measuring blow-by pressure ......................................................................................................................... 16 Testing engine oil pressure ........................................................................................................................... 17 Measuring intake air (boost) pressure........................................................................................................... 18 Handling fuel system equipment ................................................................................................................... 20 Releasing residual pressure in fuel system................................................................................................... 20 Measuring fuel pressure................................................................................................................................ 21 Measuring fuel return rate and leakage ........................................................................................................ 23 Bleeding air from fuel circuit.......................................................................................................................... 27 Checking leakage in fuel system................................................................................................................... 28 Handling cylinder cut-out mode operation..................................................................................................... 29 Handling no-injection cranking operation ...................................................................................................... 29 Handling controller voltage circuit ................................................................................................................. 30 Check of muffler and muffler stack for looseness and damage .................................................................... 30 Check of muffler function .............................................................................................................................. 31 Check of installed condition of cylinder head and manifolds......................................................................... 31 Check of engine piping for damage and looseness ...................................................................................... 32 Testing and adjusting air conditioner compressor belt tension...................................................................... 32 Replacing alternator belt ............................................................................................................................... 33 102 Testing and adjusting, Part 2 SEN05306-03 Checking operating force of accelerator pedal.............................................................................................. 3 Checking directional lever ............................................................................................................................. 4 Testing and adjusting HST oil pressure......................................................................................................... 5 Testing clutch control pressure...................................................................................................................... 10 Testing and adjusting steering wheel ............................................................................................................ 11 Testing and adjusting steering oil pressure ................................................................................................... 13 Bleeding air from steering circuit................................................................................................................... 15 Testing hydraulic fan ..................................................................................................................................... 16 Measuring brake pedal.................................................................................................................................. 18 Testing and adjusting brake pedal linkage .................................................................................................... 19 Measuring brake performance ...................................................................................................................... 20 Testing and adjusting accumulator charge pressure..................................................................................... 21 Testing wheel brake oil pressure................................................................................................................... 23 Testing wear of brake disc............................................................................................................................. 26 Bleeding air from wheel brake circuit ............................................................................................................ 27 Releasing residual pressure in brake accumulator circuit ............................................................................. 28 Testing parking brake performance............................................................................................................... 29 Testing and adjusting parking brake control cable ........................................................................................ 30 Measuring and adjusting work equipment control lever ................................................................................ 31 Testing and adjusting work equipment hydraulic pressure............................................................................ 32 Testing work equipment PPC oil pressure .................................................................................................... 33 Bleeding air from hydraulic circuit ................................................................................................................. 35 Releasing remaining pressure in hydraulic circuit......................................................................................... 36 Testing and adjusting bucket positioner ........................................................................................................ 37 Testing and adjusting boom kick-out switch .................................................................................................. 39 Checking proximity switch operation pilot lamp ............................................................................................ 40 Procedure for testing diodes ......................................................................................................................... 41 Preparation work for troubleshooting for electric system .............................................................................. 43
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WA200, 200PZ-6
100 Index Table of contents
SEN05291-07
Starting KOMTRAX terminal operations ........................................................................................................ 47 Indicator lamps of KOMTRAX terminal.......................................................................................................... 51 Adjustment of rearview camera angle ........................................................................................................... 54 103 Testing and adjusting, Part 3 SEN05307-02 Adjusting machine monitor ............................................................................................................................ 2 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3 Special functions of machine monitor (EMMS).............................................................................................. 5 Pm clinic inspection chart .............................................................................................................................. 59 40 Troubleshooting 100 Failure code table and fuse locations SEN05308-01 Failure codes table ........................................................................................................................................ 2 Fuse locations ............................................................................................................................................... 8 200 General information on troubleshooting SEN05309-01 Points to remember when troubleshooting .................................................................................................... 2 Sequence of events in troubleshooting ......................................................................................................... 3 Testing before troubleshooting ...................................................................................................................... 4 Classification and procedures of troubleshooting .......................................................................................... 5 Information contained in troubleshooting table .............................................................................................. 8 Connection table for connector pin numbers ................................................................................................. 10 T- branch box and T- branch adapter table ................................................................................................... 46 301 Troubleshooting by failure code (Display of code), Part 1 SEN05310-00 Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2 Failure code [6091NX] HST filter: Clogging................................................................................................... 4 Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 5 Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 6 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage .................. 8 Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 10 Failure code [B@BCNS] Engine: Overheat................................................................................................... 11 Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 12 Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 14 Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 15 302 Troubleshooting by failure code (Display of code), Part 2 SEN05311-00 Failure code [CA111] Abnormality in engine controller .................................................................................. 3 Failure code [CA115] Engine Ne or Bkup speed sensor error....................................................................... 4 Failure code [CA122] Charge pressure sensor high error............................................................................. 6 Failure code [CA123] Charge pressure sensor low error .............................................................................. 8 Failure code [CA131] Throttle sensor high error ........................................................................................... 10 Failure code [CA132] Throttle sensor low error............................................................................................. 12 Failure code [CA144] Coolant sensor high error ........................................................................................... 14 Failure code [CA145] Coolant sensor low error............................................................................................. 16 Failure code [CA153] Charge temperature sensor high error ....................................................................... 18 Failure code [CA154] Charge temperature sensor low error......................................................................... 20 Failure code [CA155] Derating of speed by abnormally high charge temperature........................................ 22 Failure code [CA187] Sensor power supply 2 low error ................................................................................ 24 Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 26 Failure code [CA222] Atmospheric sensor low error ..................................................................................... 28 Failure code [CA227] Sensor power supply 2 high error............................................................................... 30 Failure code [CA234] Engine overspeed....................................................................................................... 31 Failure code [CA238] Ne speed sensor power supply error.......................................................................... 32 Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 33 Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34 Failure code [CA322] Injector #1 open/short error ........................................................................................ 36 Failure code [CA324] Injector #3 open/short error ........................................................................................ 38 Failure code [CA331] Injector #2 open/short error ........................................................................................ 40 Failure code [CA332] Injector #4 open/short error ........................................................................................ 42 Failure code [CA342] Calibration code inconsistency ................................................................................... 44 WA200, 200PZ-6
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Failure code [CA351] Injectors drive circuit error .......................................................................................... 46 Failure code [CA352] Sensor power supply 1 low error................................................................................ 48 Failure code [CA386] Sensor power supply 1 high error .............................................................................. 50 303 Troubleshooting by failure code (Display of code), Part 3 SEN05312-00 Failure code [CA428] Abnormally high level in water sensor........................................................................ 4 Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6 Failure code [CA431] Idle validation switch error.......................................................................................... 8 Failure code [CA432] Idle validation action error .......................................................................................... 12 Failure code [CA435] Engine oil pressure switch error ................................................................................. 16 Failure code [CA441] Battery voltage low error ............................................................................................ 17 Failure code [CA442] Battery voltage high error ........................................................................................... 20 Failure code [CA449] Common rail pressure high error 2............................................................................. 22 Failure code [CA451] Common rail pressure sensor high error.................................................................... 24 Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26 Failure code [CA488] Derating of torque by abnormally high charge temperature ....................................... 28 Failure code [CA553] Common rail pressure high error 1............................................................................. 29 Failure code [CA559] Supply pump pressure very low error......................................................................... 30 Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32 Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34 Failure code [CA757] All continuous data lost error ...................................................................................... 35 Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38 Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40 Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 42 Failure code [CA2186] Throttle sensor power supply low error .................................................................... 44 Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 46 Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 48 Failure code [CA2555] Intake heater relay disconnection error .................................................................... 50 Failure code [CA2556] Intake heater relay short circuit error........................................................................ 52 304 Troubleshooting by failure code (Display of code), Part 4 SEN05313-00 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2 Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4 Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6 Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8 Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection .................................................. 14 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16 Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 18 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 20 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 22 Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 24 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 26 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness ............. 28 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 30 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 32 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals ............. 34 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 36 Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 41 305 Troubleshooting by failure code (Display of code), Part 5 SEN05314-00 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 2 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8 Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short ........................................ 12 Failure code [DDB6KB] Parking brake indicator signal: Ground fault ........................................................... 14 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble ................................................................................................................. 16 Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20 00-100
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SEN05291-07
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22 Failure code [DDD7KY] Travel speed control dial signal: Hot short .............................................................. 24 Failure code [DDE5MA] Emergency steering operation switch: Disconnection ............................................ 26 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault ................................................................... 28 Failure code [DDK6KY] FNR lever: Hot short................................................................................................ 32 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ................................ 34 306 Troubleshooting by failure code (Display of code), Part 6 SEN05315-00 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 2 Failure code [DF10KB] Travel speed range selector switch: Hot short ......................................................... 6 Failure code [DGH1KX] HST oil temperature sensor: Ground fault .............................................................. 8 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................ 9 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short .......................................... 10 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault ............................................ 12 Failure code [DHH1KY] HST oil pressure sensor: Hot short ......................................................................... 14 Failure code [DHTCL6] HST filter clogging sensor: Functional defect .......................................................... 16 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short .............................................................. 18 Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20 Failure code [DLT4KX] Travel speed sensor A: Abnormality......................................................................... 24 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality .................................................................. 26 Failure code [DV00KY] Alarm buzzer: Hot short ........................................................................................... 28 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ........................................................ 30 Failure code [DW26KY] Motor 2 solenoid: Hot short ..................................................................................... 32 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short ................................................................... 34 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36 307 Troubleshooting by failure code (Display of code), Part 7 SEN05316-00 Failure code [DX16KA] Fan EPC solenoid: Disconnection ........................................................................... 2 Failure code [DX16KB] Fan EPC solenoid: Ground fault .............................................................................. 3 Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................................... 4 Failure code [DX19KA] Motor 1 solenoid: Disconnection .............................................................................. 6 Failure code [DX19KB] Motor 1 solenoid: Ground fault................................................................................. 8 Failure code [DX19KY] Motor 1 solenoid: Hot short ...................................................................................... 10 Failure code [DX20KA] Clutch EPC solenoid: Disconnection ....................................................................... 12 Failure code [DX20KB] Clutch EPC solenoid: Ground fault .......................................................................... 14 Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................................... 16 Failure code [DXH7KB] Reverse solenoid: Ground fault............................................................................... 18 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................. 20 Failure code [DXH8KB] Forward solenoid: Ground fault ............................................................................... 22 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................. 24 Failure code [J141N1] Steering pump: Overrun alarm .................................................................................. 26 Failure code [M100N1] HST pump: Overrun alarm ....................................................................................... 27 Failure code [M400N1] Motor 1: Overrun alarm ............................................................................................ 28 400 Troubleshooting of electrical system (E-mode) SEN05317-01 E-1 Engine does not start .............................................................................................................................. 3 E-2 Preheater does not operate normally...................................................................................................... 10 E-3 Travel speed is low or high ..................................................................................................................... 14 E-4 ECSS does not operate .......................................................................................................................... 20 E-5 ECSS keeps operating............................................................................................................................ 23 E-6 Defective boom kick-out function and cancellation ................................................................................. 26 E-7 Defective bucket positioner function and cancellation ............................................................................ 30 E-8 Defective lift arm FLOATING holding function and cancellation ............................................................. 34 E-9 Travel direction selection system does not function................................................................................ 38 E-10 Fan does not reverse ............................................................................................................................ 42 E-11 Fan keeps rotating in reverse................................................................................................................ 46 E-12 Wiper does not operate......................................................................................................................... 48 E-13 Windshield washer does not operate.................................................................................................... 52 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off ........................................................ 56 E-15 Working lamp does not light up or go off............................................................................................... 64 E-16 Turn signal lamp and hazard lamp do not light up or go off .................................................................. 69 WA200, 200PZ-6
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E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 76 E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 78 E-19 Backup alarm does not sound or it keeps sounding ............................................................................. 81 E-20 Horn does not sound or it keeps sounding ........................................................................................... 84 E-21 Alarm buzzer does not sound or it keeps sounding.............................................................................. 86 E-22 Air conditioner does not operate or stop............................................................................................... 89 E-23 The KOMTRAX system does not work properly ................................................................................... 92 E-24 Rearview monitor does not light up or backlight flickers....................................................................... 94 E-25 Rearview monitor images are not displayed clearly ............................................................................. 98 E-26 Rearview monitor brightness cannot be adjusted................................................................................. 102 E-27 Night lighting lamp of rearview monitor is abnormal ............................................................................. 106 E-28 Reverse interlock function of rearview monitor does not operate properly........................................... 109 500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN05318-00 Method of using troubleshooting chart .......................................................................................................... 3 Failure code and cause table ........................................................................................................................ 6 H-1 The machine does not start .................................................................................................................... 8 H-2 The travel speed is slow ......................................................................................................................... 9 H-3 The traction force is weak ...................................................................................................................... 10 H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11 H-5 Speed range is not shifted...................................................................................................................... 12 H-6 The steering wheel does not turn ........................................................................................................... 13 H-7 The steering wheel is heavy................................................................................................................... 14 H-8 Steering wheel shakes or jerks............................................................................................................... 15 H-9 Machine deviates naturally to one side when traveling .......................................................................... 15 H-10 The brake does not work or does not work well ................................................................................... 16 H-11 The brake is not released or is dragged ............................................................................................... 17 H-12 The lift arm does not rise or lower ........................................................................................................ 18 H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20 H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20 H-17 The lift arm wobbles during operation .................................................................................................. 20 H-18 When the control lever is switched from HOLD to RAISE, the lift arm falls temporarily .................. 21 H-19 The bucket does not tilt back................................................................................................................ 22 H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23 H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24 H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24 H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24 H-24 The bucket wobbles during travel with load (The work equipment valve is set to HOLD ) ................. 24 H-25 When the control lever is switched from HOLD to TILT, the bucket falls temporarily ...................... 25 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25 H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27 600 Troubleshooting of engine (S-mode) SEN05319-00 Method of using troubleshooting charts ........................................................................................................ 2 S-1 Starting performance is poor .................................................................................................................. 6 S-2 Engine does not start.............................................................................................................................. 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10 S-4 Engine stops during operations .............................................................................................................. 11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power)...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15 S-9 Oil becomes contaminated quickly ......................................................................................................... 16 S-10 Fuel consumption is excessive............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18 S-12 Oil pressure drops ................................................................................................................................ 19 S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20 00-100
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SEN05291-07
S-14 Coolant temperature becomes too high (overheating).......................................................................... 21 S-15 Abnormal noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ........................................................................................................................... 23 50 Disassembly and assembly 100 General information on disassembly and assembly SEN05320-00 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools ............................................................................................................................... 11 200 Engine and cooling system SEN05321-00 Removal and installation of fuel supply pump assembly ............................................................................... 2 Removal and installation of fuel injector assembly ........................................................................................ 6 Removal and installation of cylinder head assembly ..................................................................................... 14 Removal and installation of engine hood assembly ...................................................................................... 27 Removal and installation of radiator .............................................................................................................. 31 Removal and installation of air aftercooler..................................................................................................... 34 Removal and installation of hydraulic oil cooler assembly ............................................................................ 36 Removal and installation of engine assembly ............................................................................................... 38 Removal and installation of engine front oil seal assembly ........................................................................... 45 Removal and installation of engine rear oil seal assembly ............................................................................ 48 Removal and installation of cooling fan and fan motor assembly.................................................................. 51 Removal and installation of fuel tank assembly............................................................................................. 54 301 Power train, Part 1 SEN05322-01 Disassembly and assembly of transfer assembly.......................................................................................... 2 Removal and installation of parking brake assembly..................................................................................... 22 Disassembly and assembly of parking brake assembly ................................................................................ 24 302 Power train, Part 2 SEN05323-00 Removal and installation of front axle assembly ........................................................................................... 2 Removal and installation of rear axle assembly ............................................................................................ 4 Disassembly and assembly of axle housing assembly.................................................................................. 7 Disassembly and assembly of differential assembly ..................................................................................... 15 400 Undercarriage and frame SEN05324-01 Removal and installation of center hinge pin ................................................................................................. 2 Removal and installation of counterweight assembly .................................................................................... 11 500 Hydraulic system SEN05325-01 Removal and installation of HST pump and 4-gear pump assembly............................................................. 2 Disassembly and assembly of HST pump assembly..................................................................................... 6 Removal and installation of HST motor 1 assembly ...................................................................................... 33 Removal and installation of HST motor 2 assembly ...................................................................................... 35 Disassembly and assembly of HST motor assembly .................................................................................... 37 Removal and installation of work equipment control valve assembly............................................................ 53 Removal and installation of hydraulic tank .................................................................................................... 55 Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 57 600 Work equipment SEN05326-00 Removal and installation of work equipment assembly ................................................................................. 2 700 Cab and its attachments SEN05327-00 Removal and installation of operator's cab and floor frame assembly .......................................................... 2 Removal and installation of operator's cab glass (Stuck glass)..................................................................... 7 Removal and installation of air conditioner unit ............................................................................................. 15 800 Electrical system SEN05328-00 Removal and installation of monitor panel..................................................................................................... 2 Removal and installation of engine controller assembly................................................................................ 4 Removal and installation of HST controller assembly ................................................................................... 6 Removal and installation of KOMTRAX terminal assembly........................................................................... 7
WA200, 200PZ-6
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SEN05291-07
100 Index Table of contents
90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN05329-00 Hydraulic circuit diagram ............................................................................................................................... 3 200 Electrical diagrams and drawings SEN05330-01 Common electrical circuit diagram ................................................................................................................ 3 Specific electrical circuit diagram .................................................................................................................. 31 Connector list and stereogram ...................................................................................................................... 33
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WA200, 200PZ-6
100 Index Table of contents
SEN05291-07
WA200, 200PZ-6
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SEN05291-07
WA200-6, WA200PZ-6 Wheel loader Form No. SEN05291-07
©2019 KOMATSU All Rights Reserved Printed in Japan 10-19 (01)
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