Komatsu Wheel Loaders WA200L, WA200PT(L) Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA200-5L, WA200PT-5, WA200PT-5L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loaders WA200L, WA200PT(L) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM013700 - Wheel Loader GALEO WA200PT-5L Operation & Maintenance Manual.pdf
CEBM013003 - Wheel Loader GALEO WA200-5L, WA200PT-5L Shop Manual.pdf
SEBM033307 - Wheel Loader WA200-5, WA200PT-5 Shop Manual.pdf
SEBM033309 - Wheel Loader WA200-5, WA200PT-5 Shop Manual.pdf
TEN00080-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual.pdf
TEN00082-00 - Wheel Loader GALEO WA200PTL-5 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,211 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM013700 - Wheel Loader GALEO WA200PT-5L Operation & Maintenance Manual...2
COVER...2
INTRODUCTION...5
FOREWORD...6
SAFETY INFORMATION...7
INTRODUCTION...9
DIRECTIONS OF MACHINE...9
NECESSARY INFORMATION...10
MACHINE SERIAL NO. PLATE...10
ENGINE SERIAL NO. PLATE AND POSITION...10
SERVICE METER POSITION...11
ENTER SERIAL NO. AND DISTRIBUTOR...11
TABLE OF CONTENTS...12
SAFETY...23
SAFETY LABELS...24
LOCATION OF SAFETY LABELS...24
SAFETY LABELS...25
GENERAL PRECAUTIONS...31
SAFETY RULES...31
IF ABNORMALITIES ARE FOUND...31
CLOTHING AND PERSONAL PROTECTIVE ITEMS...31
FIRE EXTINGUISHER AND FIRST AID KIT...31
SAFETY FEATURES...31
KEEP THE MACHINE CLEAN...32
INSIDE OPERATOR'S COMPARTMENT...32
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...32
HANDRAILS AND STEPS...33
MOUNTING AND DISMOUNTING...34
NO PEOPLE ON ATTACHMENTS...34
DO NOT GET CAUGHT IN ARTICULATED PORTION...34
BURN PREVENTION...34
HOT COOLANT...34
HOT OIL...34
FIRE PREVENTION...35
ACTION IF FIRE OCCURS...36
WINDOW WASHER LIQUID...36
PRECAUTIONS WHEN USING ROPS...36
PRECAUTIONS FOR ATTACHMENTS...36
UNAUTHORIZED MODIFICATION...36
SAFETY AT WORK SITE...37
WORKING ON LOOSE GROUND...37
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...37
ENSURE GOOD VISIBILITY...38
BE CAREFUL ABOUT EXHAUST FUMES...38
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...38
EMERGENCY EXIT FROM OPERATOR'S CAB...38
ASBESTOS DUST HAZARD...39
PRECAUTIONS FOR OPERATION...40
BEFORE STARTING ENGINE...40
CHECKS BEFORE STARTING ENGINE...40
PRECAUTIONS WHEN STARTING...41
PRECAUTIONS IN COLD AREAS...41
CHECKS BEFORE OPERATION...41
PRECAUTIONS BEFORE MOVING FORWARD OR BACK...42
PRECAUTIONS WHEN TRAVELING...42
TRAVELING ON SLOPES...43
PROHIBITED OPERATIONS...44
PRECAUTIONS WHEN OPERATING...44
METHODS OF USING BRAKE...45
OPERATE CAREFULLY ON SNOW...45
PARKING MACHINE...46
TRANSPORTATION...47
LOADING AND UNLOADING...47
SHIPPING...47
BATTERY...48
BATTERY HAZARD PREVENTION...48
STARTING WITH BOOSTER CABLES...49
TOWING...49
WHEN TOWING...49
PRECAUTIONS FOR MAINTENANCE...50
WARNING TAG...50
KEEP WORK PLACE CLEAN AND TIDY...50
APPOINT LEADER WHEN WORKING WITH OTHERS...50
MAINTENANCE WITH ENGINE RUNNING...51
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...52
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...52
PROPER TOOLS...53
ACCUMULATOR...53
PERSONNEL...53
ATTACHMENTS...53
WORK UNDER THE MACHINE...54
NOISE...54
PRECAUTIONS WHEN USING HAMMER...54
REPAIR WELDING...54
REMOVING BATTERY TERMINAL...55
PRECAUTIONS WITH HIGH-PRESSURE OIL...55
HANDLING HIGH-PRESSURE HOSES...55
WASTE MATERIALS...55
MAINTENANCE OF AIR CONDITIONER...55
COMPRESSED AIR...56
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...56
PRECAUTIONS WITH TIRES...57
HANDLING TIRES...57
PRECAUTIONS WHEN STORING TIRES...57
OPERATION...59
GENERAL VIEW...60
GENERAL VIEW OF MACHINE...60
CONTROLS AND GAUGES...61
MACHINE MONITOR...62
EXPLANATION OF COMPONENTS...63
MACHINE MONITOR...63
MONITOR SYSTEM...64
TESTING ACTUATION OF MACHINE MONITOR SYSTEM...64
TYPES OF WARNING...65
EMERGENCY STOP...65
CAUTION...65
MISTAKEN OPERATION...65
INSPECTION AND MAINTENANCE...65
CENTRAL WARNING LAMP...65
CHARACTER DISPLAY PORTION...66
SERVICE METER...66
ACTION CODE DISPLAY...67
FAILURE CODE DISPLAY...68
FILTER, OIL REPLACEMENT TIME DISPLAY...69
EMERGENCY STOP ITEM...71
BRAKE OIL PRESSURE CAUTION LAMP...71
ENGINE OIL PRESSURE CAUTION LAMP...72
BATTERY CHARGE CIRCUIT CAUTION LAMP...72
STEERING OIL PRESSURE CAUTION LAMP - RED...72
CAUTION ITEMS...73
AXLE OIL TEMPERATURE CAUTION LAMP...73
PARKING BRAKE REMINDER CAUTION LAMP...74
HST OIL TEMPERATURE CAUTION LAMP...74
ENGINE COOLING WATER TEMPERATURE CAUTION LAMP...74
FUEL LEVEL CAUTION LAMP...75
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...75
TRAVEL SPEED LIMIT FUNCTION...75
INSPECTION AND MAINTENANCE ITEM...76
RADIATOR COOLANT LEVEL CAUTION LAMP...76
MAINTENANCE CAUTION LAMP...77
HST OIL FILTER CLOG CAUTION LAMP...77
PILOT DISPLAY PORTION...78
PARKING BRAKE PILOT LAMP...78
PREHEATING PILOT LAMP...78
AUXILIARY STEERING PILOT LAMP-GREEN...79
DIRECTIONAL LEVER POSITION PILOT LAMP...79
PILOT LAMP FOR SPEED RANGE SELECTOR SWITCH POSITION...79
TURN SIGNAL PILOT LAMP...79
HEAD LAMP HIGH BEAM PILOT LAMP...80
METER DISPLAY PORTION...81
HST OIL TEMPERATURE GAUGE...81
ENGINE COOLANT TEMPERATURE GAUGE...81
FUEL GAUGE...82
SPEEDOMETER...82
METER DISPLAY PILOT LAMP...82
OTHER FUNCTIONS OF MACHINE MONITOR...83
METHOD OF DISPLAYING ODOMETER...83
RESET METHOD FOR FILTER, OIL REPLACEMENT TIME...83
METHOD FOR SELECTING LANGUAGE...84
METHOD OF SELECTING HST CHANGING FUNCTION...85
SWITCHES...86
STARTING SWITCH...86
SPEED RANGE SELECTOR SWITCH...87
VARIABLE SHIFT CONTROL SWITCH...87
DIRECTIONAL SELECTOR SWITCH...87
DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH...88
TRACTION CONTROL SWITCH...88
E.C.S.S. SWITCH...89
LAMP SWITCH...89
TURN SIGNAL LEVER...90
DIMMER SWITCH...90
HORN BUTTON...90
HAZARD LAMP SWITCH...91
FRONT WORKING LAMP SWITCH...91
REAR WORKING LAMP SWITCH...92
MONITOR PANEL MODE SELECTOR SWITCH 1...92
MONITOR PANEL MODE SELECTOR SWITCH 2...92
FRONT WIPER SWITCH...93
REAR WIPER SWITCH...93
CIGARETTE LIGHTER...93
ROOM LAMP SWITCH...93
REAR HEATED WIRE GLASS SWITCH...94
ATTACHMENT SELECTION SWITCH...94
DUMP SPEED SWITCH...94
QUICK COUPLER ATTACHMENT SWITCH...94
CONTROL LEVERS, PEDALS...95
DIRECTIONAL LEVER...95
SAFETY LOCK LEVER (FOR WORK EQUIPMENT LEVER)...96
WORK EQUIPMENT LEVER...96
AUXILIARY CONTROL LEVER...97
BRAKE PEDAL...97
ACCELERATOR PEDAL...98
PARKING BRAKE LEVER...98
STEERING TILT LOCK LEVER...99
CAP AND COVER WITH LOCK...99
METHOD OF OPENING AND CLOSING CAP WITH LOCK...99
FUEL TANK FILLER PORT...99
ENGINE SIDE COVER...100
SAFETY BAR...100
TOWING PIN...101
GREASE PUMP...101
CAB DOOR INNER LOCK...102
CAB DOOR OPEN LOCK...102
CAB WINDOW OPEN LOCK CANCEL KNOB...102
FUSE...103
FUSE CAPACITY AND NAME OF CIRCUIT...103
SLOW BLOW FUSE...104
AUXILIARY POWER...105
STORAGE BOX...105
AM/FM RADIO-CASSETTE...106
EXPLANATION OF COMPONENTS...106
POWER SWITCH/VOLUME...107
AUTO-STORE/PRESET SCAN BUTTON...107
BASS CONTROL KNOB...107
TREBLE CONTROL KNOB...108
LOUDNESS BUTTON...108
TIME/RADIO DISPLAY SELECTOR BUTTON...108
TAPE EJECT BUTTON...109
CASSETTE DOOR...109
FAST FORWARD, REWIND BUTTONS...109
PRESET BUTTONS...109
METAL TAPE BUTTON...110
MANUAL TUNING BUTTONS...110
SEEK TUNING BUTTONS...110
BAND SELECTOR BUTTON...110
METHOD OF OPERATION...111
METHOD OF AUTO PRESET...111
METHOD OF MANUAL PRESET...111
LISTENING TO RADIO...112
LISTENING TO CASSETTE TAPE...112
REVERSING TAPE...113
PRECAUTIONS WHEN USING...113
AIR CONDITIONER...114
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL...114
FAN SWITCH...114
AIR CONDITIONER SWITCH...114
MODE SELECTOR SWITCH...115
FRESH/RECIRC SELECTOR SWITCH...115
TEMPERATURE CONTROL SWITCH...115
METHOD OF OPERATION...116
WHEN NOT USING THE AIR CONDITIONER REGULARLY...117
COOL BOX...117
PRECAUTIONS WHEN USING...117
PRECAUTIONS WHEN USING THE COOLING...117
HANDLING CAB WIPER...117
PREVENTING WIPER ARM BRACKET DAMAGE...117
OPERATION...118
CHECK BEFORE STARTING ENGINE, ADJUST...118
WALK-AROUND CHECK...118
CHECK BEFORE STARTING...121
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...121
CHECK WATER SEPARATOR...122
CHECK DUST INDICATOR...122
CHECK COOLANT LEVEL, ADD COOLANT...123
CHECK INFLATION PRESSURE OF TIRES...123
CHECK ELECTRIC WIRING...124
CHECK MONITOR PANEL...124
CHECK FUEL LEVEL, ADD FUEL...125
CHECK PARKING BRAKE...126
CHECK BRAKE PEDAL...126
ADJUSTMENT...126
SEAT ADJUSTMENT...126
ADJUST SEAT BELT...128
ADJUST LEVER STAND...128
ADJUST REAR VIEW MIRROR...129
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...130
STARTING ENGINE...132
OPERATIONS AND CHECKS AFTER STARTING ENGINE...134
BREAKING-IN THE MACHINE...134
NORMAL OPERATION...135
STOPPING ENGINE...136
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...137
MOVING THE MACHINE...137
CHANGING DIRECTION...139
CHANGING BETWEEN FORWARD AND REVERSE...139
STOPPING THE MACHINE...141
TURNING...142
AUXILIARY STEERING...143
OPERATION OF WORK EQUIPMENT...143
LIFT ARM OPERATION...144
BUCKET OPERATION...144
HANDLING HYDRAULIC QUICK COUPLER...145
REMOVING THE ATTACHMENT...145
INSTALLING THE ATTACHMENT...146
WORK POSSIBLE USING WHEEL LOADER...148
DIGGING OPERATIONS...148
LOADING PILED SOIL...148
DIGGING AND LOADING ON LEVEL GROUND...149
LEVELING OPERATIONS...150
PUSHING OPERATION...150
LOAD AND CARRY OPERATIONS...150
LOADING OPERATIONS...151
CROSS DRIVE LOADING...151
V-SHAPE LOADING...152
PRECAUTIONS WHEN PILING UP LOADS...152
PRECAUTIONS FOR OPERATION...152
PERMISSIBLE WATER DEPTH...152
IF WHEEL BRAKE DOES NOT WORK...152
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...153
LOWER THE CENTER OF GRAVITY WHEN TURNING...153
BRAKING ON DOWNHILL SLOPE...153
IF ENGINE STOPS...153
PRECAUTIONS WHEN DRIVING MACHINE...153
ADJUSTING WORK EQUIPMENT POSTURE...154
ADJUSTING BOOM KICKOUT...154
ADJUSTING BUCKET POSITIONER...155
ADJUSTING FORK POSITIONER...156
BUCKET LEVEL INDICATOR...157
PARKING MACHINE...158
CHECKS AFTER COMPLETION OF OPERATION...159
WITH ENGINE RUNNING...159
AFTER ENGINE SHUT DOWN...159
LOCKING...160
HANDLING THE TIRES...161
PRECAUTIONS WHEN HANDLING TIRES...161
TIRE PRESSURE...161
PRECAUTIONS FOR USING LOAD AND CARRY METHOD...162
TRANSPORTATION...163
TRANSPORTATION PROCEDURE...163
LOADING, UNLOADING WORK WITH TRAILERS...163
LOADING...163
SECURING MACHINE...164
UNLOADING...164
LIFTING MACHINE...165
LOCATION OF LIFTING POSITION MARK...166
WEIGHT TABLE...166
LIFTING PROCEDURE...167
COLD WEATHER OPERATION...168
PRECAUTIONS FOR LOW TEMPERATURE...168
FUEL AND LUBRICANTS...168
COOLANT...168
BATTERY...169
PRECAUTIONS AFTER COMPLETION OF WORK...169
AFTER COLD WEATHER...170
STEERING HYDRAULIC CIRCUIT WARM UP...170
LONG TERM STORAGE...171
BEFORE STORAGE...171
DURING STORAGE...171
AFTER STORAGE...171
TROUBLESHOOTING...172
WHEN MACHINE RUNS OUT OF FUEL...172
TOWING THE MACHINE...172
WHEN ENGINE CAN BE USED...173
WHEN ENGINE CANNOT BE USED...173
EMERGENCY TRAVEL OPERATION...173
IF BATTERY IS DISCHARGED...173
REMOVAL AND INSTALLATION OF BATTERY...174
PRECAUTIONS FOR CHARGING BATTERY...175
STARTING ENGINE WITH BOOSTER CABLE...175
OTHER TROUBLE...177
ELECTRICAL SYSTEM...177
CHASSIS...178
ENGINE...180
MAINTENANCE...183
GUIDES TO MAINTENANCE...184
CHECK SERVICE METER...184
KOMATSU GENUINE REPLACEMENT PARTS...184
KOMATSU GENUINE OILS...184
ALWAYS USE CLEAN WASHER FLUID...184
ALWAYS USE CLEAN OIL AND GREASE...184
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS...184
FUEL STRAINER...184
WELDING INSTRUCTIONS...184
DO NOT DROP THINGS INSIDE MACHINE...184
DUSTY WORK SITES...185
AVOID MIXING OIL...185
LOCKING INSPECTION COVERS...185
BLEEDING AIR FROM HYDRAULIC CIRCUIT...185
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES...185
CHECKS AFTER INSPECTION AND MAINTENANCE...185
OUTLINES OF SERVICE...186
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...186
OIL...186
FUEL...186
COOLANT...186
GREASE...187
KOWA (Komatsu Oil Wear Analysis)...187
STORING OIL AND FUEL...188
FILTERS...188
OUTLINE OF ELECTRIC SYSTEM...188
WEAR PARTS...189
WEAR PARTS LIST...189
FLUID USE ACCORDING TO AMBIENT TEMPERATURE...190
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...190
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...194
TORQUE LIST...194
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...195
MAINTENANCE SCHEDULE CHART...196
SERVICE PROCEDURE...198
INITIAL 250 HOURS SERVICE...198
REPLACE HST OIL FILTER ELEMENT...227
REPLACE HYDRAULIC TANK FILTER ELEMENT...229
WHEN REQUIRED...198
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...198
CHECKING...198
CLEANING OUTER ELEMENT...199
REPLACING ELEMENT...200
CLEAN INSIDE OF COOLING SYSTEM...201
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...204
CHECK AXLE OIL LEVEL, ADD OIL...205
CLEAN AXLE CASE BREATHER...206
CLEAN AIR CONDITIONER CONDENSER...206
WASHING METHOD...206
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...207
CLEAN RADIATOR FINS AND COOLER FINS...207
CLEAN TRANSFER OIL COOLER FINS...207
CHECK ELECTRICAL INTAKE AIR HEATER...208
REPLACE BOLT-ON CUTTING EDGE...208
REPLACE BUCKET TEETH...209
ONE-PIECE TOOTH...209
BUCKET WITH TIP TOOTH...209
CHECK AIR CONDITIONER...210
OPERATING THE AIR CONDITIONER OFF SEASON...210
REPLACE SLOW BLOW FUSE...211
SELECTION AND INSPECTION OF TIRES...212
SELECTION OF TIRES...212
CHECK INFLATION PRESSURE OF TIRES...213
CHECK BEFORE STARTING...214
EVERY 50 HOURS SERVICE...215
DRAIN WATER, SEDIMENT FROM FUEL TANK...215
EVERY 100 HOURS SERVICE...215
LUBRICATE REAR AXLE PIVOT PIN...215
CLEAN AIR CONDITIONER FRESH AIR FILTER ELEMENT...215
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...216
EVERY 250 HOURS SERVICE...217
CHECK BATTERY ELECTROLYTE LEVEL...217
CHECK PARKING BRAKE...219
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...219
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...220
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...220
LUBRICATING...221
EVERY 500 HOURS SERVICE...222
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...222
REPLACE FUEL FILTER CARTRIDGE...223
CLEAN WATER SEPARATOR STRAINER...224
EVERY 1000 HOURS SERVICE...225
CHANGE OIL IN TRANSFER CASE...225
CLEAN TRANSFER CASE BREATHER...226
REPLACE HST OIL FILTER ELEMENT...227
LUBRICATING...228
CHECK TIGHTENING PARTS OF TURBOCHARGER...228
CHECK PLAY OF TURBOCHARGER ROTOR...228
CHECK FAN BELT TENSION, REPLACE...228
EVERY 2000 HOURS SERVICE...229
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...229
REPLACE HYDRAULIC TANK BREATHER ELEMENT...230
CHANGE AXLE OIL...231
REPLACE AIR CONDITIONER RECIRCULATION AIR FILTER AND FRESH AIR FILTER ELEMENTS...231
CLEAN BRAKE CIRCUIT STRAINER...232
CHECK ALTERNATOR, STARTING MOTOR...232
CHECK ENGINE VALVE CLEARANCE, ADJUST...232
CHECK BRAKE DISC WEAR...233
CLEAN AND CHECK TURBOCHARGER...234
CHECK ACCUMULATOR GAS PRESSURE...234
CHECK VIBRATION DAMPER...234
EVERY 4000 HOURS SERVICE...235
LUBRICATING...235
CHECK WATER PUMP...235
SPECIFICATIONS...237
SPECIFICATIONS...238
WA200PT-5L WITH BOLT-ON CUTTING EDGE...238
OPTIONS, ATTACHMENTS...241
BUCKETS AND TIRES SELECTION...242
HANDLING FORK TOOL...243
EXPLANATION OF COMPONENTS...243
WORK EQUIPMENT LEVER...243
OPERATION...244
LOADING OPERATION...244
LOADING...244
TRANSPORTING...245
UNLOADING...246
CEBM013003 - Wheel Loader GALEO WA200-5L, WA200PT-5L Shop Manual...249
COVER...249
FOREWORD...250
CONTENTS...250
SAFETY...259
SAFETY NOTICE...259
IMPORTANT SAFETY NOTICE...259
GENERAL PRECAUTIONS...259
PREPARATIONS FOR WORK...259
PRECAUTIONS DURING WORK...259
GENERAL...261
HOW TO READ THE SHOP MANUAL...262
VOLUMES...262
DISTRIBUTION AND UPDATING...262
FILING METHOD...262
REVISED EDITION MARK...262
REVISIONS...262
SYMBOLS...262
HOISTING INSTRUCTIONS...263
HOISTING...263
WIRE ROPES...263
COATING MATERIALS...266
STANDARD TIGHTENING TORQUE...268
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...268
TIGHTENING TORQUE OF HOSE NUTS...269
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...269
TIGHTENING TORQUE FOR FLARED NUTS...269
ELECTRIC WIRE CODE...273
CLASSIFICATION BY THICKNESS...273
CLASSIFICATION BY COLOR AND CODE...273
CONVERSION TABLES...274
METHOD OF USING THE CONVERSION TABLE...274
01 GENERAL...281
GENERAL ASSEMBLY DRAWINGS...282
SPECIFICATIONS...283
WEIGHT TABLE...287
FLUID USE ACCORDING TO AMBIENT TEMPERATURE...288
COOLANT SPECIFICATIONS...290
SUPERCOOLANT (AF-NAC)...290
10 STRUCTURE AND FUNCTION...291
ENGINE AND DRIVE SYSTEM MOUNTING...297
DRIVE SYSTEM DAMPER...298
COOLING SYSTEM...299
REVERSING FAN SYSTEM...300
REVERSING FAN MANIFOLD...301
PROPORTIONAL RELIEF VALVE...302
2-POSITION, 4-WAY SPOOL VALVE...303
FAN CONTROLLER...304
POWER TRAIN...306
POWER TRAIN SYSTEM DIAGRAM...307
DRIVE SHAFT...309
HST HYDRAULIC PIPING DIAGRAM...310
HST PUMP...311
OPERATION...312
FLOW OF OIL...313
HIGH-PRESSURE RELIEF VALVE...314
LOW-PRESSURE RELIEF VALVE...316
CHARGE PUMP...317
SPEED-RELATED VALVE (DA VALVE)...318
HIGH-PRESSURE CUT-OFF VALVE...319
HST MOTOR...320
HST MOTOR 1...320
HST MOTOR 2...322
EP SERVO VALVE...324
HA SERVO VALVE...325
FORWARD-REVERSE SHUTTLE VALVE...326
TRANSFER...327
OUTLINE...327
INPUT SHAFT PORTION...330
OUTPUT SHAFT PORTION...332
CLUTCH OPERATION...335
LOW-SPEED MODE...336
HIGH-SPEED MODE...337
CLUTCH SOLENOID VALVE...338
OPERATION...338
AXLE...339
FRONT AXLE...339
REAR AXLE...340
DIFFERENTIAL...341
FRONT DIFFERENTIAL...341
REAR DIFFERENTIAL...343
OUTLINE...345
LIMITED SLIP DIFFENTIAL...346
OPERATION...347
WHEN TRAVELING IN A STRAIGHT LINE...348
WHEN TURNING...349
FINAL DRIVE...350
OUTLINE...351
AXLE MOUNTING AND CENTER HINGE PIN...352
OUTLINE...353
STEERING PIPING SYSTEM...356
STEERING COLUMN...357
PRIORITY VALVE...358
OUTLINE...359
OPERATION...359
STRAIGHT TRAVEL...359
STEERING WHEEL TURNED TO LEFT...360
STEERING CYLINDER AT END OF STROKE...360
ORBIT-ROLL VALVE...361
OUTLINE...362
STRUCTURE...362
OPERATION...363
STEERING WHEEL AT NEUTRAL...363
STEERING WHEEL TURNED (TURNING LEFT)...365
STEERING WHEEL STOPPED...366
CONNECTION BETWEEN HAND PUMP AND SLEEVE...367
ROLE OF CENTERING SPRING...368
2-WAY RESTRICTOR VALVE...369
FUNCTION...369
OPERATION...369
CUSHION VALVE...370
OUTLINE...370
FUNCTION...370
STEERING CYLINDER...371
EMERGENCY STEERING PIPING...373
EMERGENCY STEERING VALVE...374
OPERATION...375
WHEN ENGINE AND STEERING PUMP ARE NORMAL...375
WHEN ENGINE OR STEERING PUMP IS ABNORMAL...376
BRAKE PIPING...377
BRAKE VALVE...378
OUTLINE...379
OPERATION...379
WHEN BRAKE PEDAL IS PRESSED...379
WHEN BALANCED...380
WHEN BRAKE PEDAL IS RELEASED...381
INCHING VALVE...382
OUTLINE...382
CHARGE VALVE...383
FUNCTION...384
OPERATION...385
WHEN OIL IS NOT SUPPLIED TO ACCUMULATOR...385
WHEN OIL IS SUPPLIED TO ACCUMULATOR...385
WHEN INPUT PRESSURE TO VALVE RISES ABOVE SET PRESSURE...386
BRAKE ACCUMULATOR...387
FUNCTION...387
SPECIFICATIONS...387
SLACK ADJUSTER...388
FUNCTION...389
OPERATION...389
WHEN BRAKE IS APPLIED...389
WHEN BRAKE IS RELEASED...389
BRAKE...390
OUTLINE...391
WHEN BRAKE IS APPLIED...391
WHEN BRAKE IS RELEASED...391
PARKING BRAKE CONTROL...392
OUTLINE...392
PARKING BRAKE...393
OUTLINE...393
HYDRAULIC PIPING...394
WA200-5L...394
WA200PT-5L...396
OUTLINE...397
WORK EQUIPMENT LEVER LINKAGE...398
WA200-5L...398
MULTI-FUNCTION JOYSTICK...398
STANDARD JOYSTICK...399
WA200PT-5L...400
MULTI-FUNCTION JOYSTICK...400
STANDARD JOYSTICK...401
HYDRAULIC TANK...402
SPECIFICATIONS...403
BREATHER...403
PREVENTION OF NEGATIVE PRESSURE IN TANK...403
PREVENTION OF RISE OF PRESSURE IN TANK...403
4-GEAR PUMP UNIT...404
OUTLINE...404
PPC CIRCUIT ACCUMULATOR...406
OUTLINE...406
SPECIFICATIONS...406
LOCK VALVE...406
OUTLINE...406
BYPASS VALVE...407
BOOM CYLINDER (WA200-5L AND WA200PT-5L)...407
OPERATION...408
BUCKET CYLINDER (WA200PT-5L)...410
OPERATION...411
QUICK COUPLER SOLENOID VALVE...413
OUTLINE...413
E.C.S.S. VALVE...414
ECSS ACCUMULATOR...416
FUNCTION...416
SPECIFICATIONS...416
HYDRAULIC PIPING OF COOLING SYSTEM...417
OUTLINE...417
COOLING FAN MOTOR...418
SPECIFICATIONS...418
FUNCTION...419
PRINCIPLE OF OPERATION...419
WORK EQUIPMENT CONTROL VALVE...420
2-SPOOL VALVE...420
3-SPOOL VALVE...423
RELIEF VALVE...426
SAFETY-SUCTION VALVE...427
SUCTION VALVE...428
OPERATION OF THE WORK EQUIPMENT CONTROL VALVE...429
WORK EQUIPMENT PPC VALVE...435
MONO-LEVER TYPE...435
OPERATION...437
ATTACHMENT PPC VALVE...440
OPERATION...442
AT THE NEUTRAL POSITION...442
AT THE FINE CONTROL POSITION...442
AT FULL STROKE...443
WORK EQUIPMENT LINKAGE...444
WA200-5L...444
WA200PT-5L...446
BUCKET...448
CONTROL FOR BUCKET AND BOOM...450
FOR WA200-5L...450
OUTLINE...451
OPERATION OF PROXIMITY SWITCH...452
FUNCTION OF PROXIMITY SWITCH...454
OPERATION OF BOOM KICK-OUT...455
FUNCTION OF PROXIMITY SWITCH...457
FOR WA200PT-5L...458
OUTLINE...459
BUCKET POSITIONER OR FORK POSITIONER...459
BOOM KICK-OUT...459
DUMP SPEED CONTROL...459
OPERATION OF PROXIMITY SWITCH...460
WHEN BUCKET IS TILTED...460
FUNCTION OF PROXIMITY SWITCH...462
WHEN LIFT ARM IS RAISED...463
FUNCTION OF PROXIMITY SWITCH...465
WHEN BUCKET IS DUMPED...466
FUNCTION OF PROXIMITY SWITCH...467
WORK EQUIPMENT CYLINDER...468
WA200-5L...468
LIFT CYLINDER...468
BUCKET CYLINDER...468
WA200PT-5L...469
LIFT CYLINDER...469
BUCKET CYLINDER...469
COUPLER PLUNGER...469
AIR CONDITIONER...471
AIR CONDITIONER PIPING...471
MACHINE MONITORING SYSTEM...472
OUTLINE...472
NORMAL MODE...472
SERVICE MODE...473
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR...475
STARTING AND LIGHTING...475
POWER SUPPLY AND NETWORK...477
SENSING...478
HST SAFETY CONTROL...479
AUTOMATIC PREHEATING...480
MACHINE MONITOR...481
LIST OF ITEMS DISPLAYED ON MONITOR...482
SERVICE MODE FUNCTIONS...488
OUTLINE...488
OPERATING METHOD...490
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM...491
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM...494
REAL-TIME MONITOR FUNCTION...496
MAINTENANCE FUNCTIONS...499
FUNCTION OF SELECTING OPTIONAL DEVICE...503
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...507
SYSTEM DIAGRAM...507
CONTROL FUNCTION...507
HST CONTROLLER...510
INPUT AND OUTPUT SIGNALS...510
DIRECTIONAL SELECTOR SWITCH...511
OUTLINE...511
FUNCTION...511
OPERATION...512
WHEN TRAVEL DIRECTION IS CHANGED WITH DIRECTIONAL LEVER...512
WHEN DIRECTIONAL SELECTOR SWITCH IS SELECTED TO BE USED...512
WHEN TRAVEL DIRECTION IS CHANGED WITH DIRECTIONAL SELECTOR SWITCH...512
WHEN DIRECTIONAL LEVER HAS PRIORITY...512
ENGINE STARTING CIRCUIT...513
FUNCTION...513
OPERATION...514
ENGINE STOP CIRCUIT...515
OPERATION...515
PREHEATING CIRCUIT (AUTOMATIC PREHEAT SYSTEM)...516
OUTLINE...516
OPERATION...516
PARKING BRAKE CIRCUIT...517
OPERATION...518
WHEN PARKING BRAKE LEVER IS RETURNED (ON o OFF)...518
WHEN PARKING BRAKE LEVER IS PULLED (OFF to ON)...519
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...520
FUNCTION...520
COUPLER PLUNGER CONTROL SYSTEM...521
WA200PT-5L...521
OUTLINE...521
OPERATION...521
SENSORS...522
ENGINE SPEED SENSOR...522
FUNCTION...522
SPEED SENSOR...522
FUNCTION...522
ENGINE OIL PRESSURE SENSOR...523
FUNCTION...523
FUEL LEVEL SENSOR...523
FUNCTION...523
COOLANT AND HST OIL TEMPERATURE SENSOR (FOR MONITOR)...524
FUNCTION...524
COOLANT TEMPERATURE SENSOR (FOR PREHEATING)...524
FUNCTION...524
AXLE OIL TEMPERATURE SENSOR...525
FUNCTION...525
HST OIL PRESSURE SENSOR...525
FUNCTION...525
STEERING AND EMERGENCY STEERING OIL PRESSURE SENSOR...526
FUNCTION...526
HST FILTER CLOGGING SENSOR...526
FUNCTION...526
COOLANT LEVEL SENSOR...527
FUNCTION...527
20 TESTING, ADJUSTING AND TROUBLESHOOTING...529
STANDARD VALUE TABLE...531
ENGINE...531
CHASSIS...532
SPECIAL TOOLS...538
T-ADAPTER PROCEDURES AND KITS...541
ENGINE COMPONENTS...542
MEASURING EXHAUST SMOKE...542
MEASURING EXHAUST TEMPERATURE...542
ADJUSTING VALVE CLEARANCE...542
MEASURING COMPRESSION PRESSURE...542
MEASURING CRANKCASE PRESSURE...542
MEASURING ENGINE OIL PRESSURE...542
MEASURING BOOST PRESSURE...542
MEASURING FUEL PRESSURE...542
ADJUSTING ENGINE SPEED SENSOR...542
BLEEDING AIR FROM FUEL SYSTEM...542
MEASURING ENGINE SPEED...543
MEASURING (LOW AND HIGH IDLE)...543
MEASURING HST STALL SPEED...544
MEASURING HYDRAULIC STALL...544
MEASURING FULL STALL SPEED...544
MEASURING, OPERATING FORCE OF ACCELERATOR PEDAL...545
TESTING OPERATING FORCE...545
OPERATING ANGLE OF PEDAL...546
ADJUSTING ENGINE STOP SOLENOID...547
ADJUSTING ENGINE SPEED SENSOR...548
REFRIGERENT COMPRESSOR BELT...549
MEASURING DIRECTIONAL LEVER...550
HST OIL PRESSURE...551
MEASURING...551
ADJUSTING...554
MEASURING CLUTCH CONTROL PRESSURE...556
STEERING WHEEL...557
MEASURING WHEEL END PLAY...557
MEASURING OPERATING FORCE...557
MEASURING OPERATING TIME...558
STEERING OIL PRESSURE...559
MEASURING MAIN RELIEF PRESSURE...559
ADJUSTING MAIN RELIEF PRESSURE...559
BLEEDING AIR FROM STEERING CIRCUIT...560
HYDRAULIC FAN...561
MEASURING FAN SPEED...561
MEASURING OIL PRESSURE...562
MEASURING BRAKE PEDAL...564
BRAKE PEDAL LINKAGE...565
MEASURING BRAKE PERFORMANCE...566
ACCUMULATOR CHARGE PRESSURE...567
MEASURING BRAKE OIL PRESSURE...568
MEASURING WEAR ON BRAKE DISC...570
BLEEDING AIR FROM BRAKE CIRCUIT...571
PARKING BRAKE PERFORMANCE...572
PARKING BRAKE LINKAGE...573
WORK EQUIPMENT CONTROL LEVER...574
WORK EQUIPMENT PRESSURE...575
WORK EQUIPMENT PPC OIL PRESSURE...576
TESTING AND ADJUSTING...576
BLEEDING AIR...578
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...579
BUCKET POSITIONER...580
BOOM KICK-OUT...581
CHECKING PROXIMITY SWITCH...582
CONNECTING T-ADAPTER TO HST CONTROLLER...583
SPECIAL FUNCTIONS OF MACHINE MONITOR...586
FLOW OF MODES AND FUNCTIONS...587
PM CLINIC INSPECTION CHART...604
TROUBLESHOOTING (GENERAL)...607
POINTS TO REMEMBER WHEN TROUBLESHOOTING...608
SEQUENCE OF EVENTS IN TROUBLESHOOTING...610
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...611
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT...611
HANDLING CONTROL BOX...616
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS...617
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...618
CHECKS BEFORE TROUBLESHOOTING...620
USING TROUBLESHOOTING CHARTS...621
PHENOMENA CONSIDERED TO BE FAILURES...622
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...625
T-ADAPTER TABLE...649
CONNECTOR TYPES AND MOUNTING LOCATIONS...652
CONNECTOR LAYOUT DRAWING...658
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)...663
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...664
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL...664
USER CODE MEMORY RETENTION FUNCTION...664
HST CONTROLLER SYSTEM DIAGRAM...665
TROUBLESHOOTING CODE DISPLAY...667
ERROR CODE AND POSSIBLE CAUSE TABLE...667
FUSE SYSTEM CHECK...668
FUSE PANNEL CONNECTION TABLE...668
INFORMATION CONTAINED IN TESTING PROCEDURES...669
CODE KEY TABLE...670
ERROR CODE: [989F00]...671
TRANSMISSION PROTECTION ALERT (00)...671
ERROR CODE: [DDD7KX]...672
SPEEDOMETER SYSTEM INPUT SIGNAL OUT OF RANGE...672
ERROR CODE: [DHH1KX]...675
HST OIL PRESSURE SIGNAL OUT OF RANGE...675
ERROR CODE: [DLE2LC]...677
ENGINE SPEED SENSOR OUT OF RANGE...677
ERROR CODE: [DLT3KA]...679
TRAVEL SPEED DOES NOT REGISTER ON SPEEDOMETER...679
ERROR CODE: [DW26KZ]...682
MOTOR 2 SOLENOID SYSTEM OPEN OR SHORTED...682
ERROR CODE: [DX19KZ]...686
MOTOR 1 SOLENOID SYSTEM OPEN OR SHORTED...686
ERROR CODE: [DX20KZ]...688
CLUTCH SOLENOID SYSTEM OPEN OR SHORTED...688
TROUBLESHOOTING CODE: [HST-1]...690
DEFECTIVE HST POWER CONTROLLER SOURCE...690
TROUBLESHOOTING CODE: [HST-2]...694
TRAVEL SPEED RANGES DO NOT CHANGE...694
TROUBLESHOOTING CODE: [HST-3]...698
TRACTION CONTROL FOR HST SYSTEM CANNOT BE CONTROLLED...698
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)...701
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...704
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL...704
USER CODE MEMORY RETENTION FUNCTION...704
MONITOR SYSTEM CIRCUIT DIAGRAM...705
TROUBLESHOOTING CODE DISPLAY...709
ERROR CODE AND POSSIBLE CAUSE TABLE...709
FUSE SYSTEM CHECK...710
FUSE PANEL CONNECTION TABLE...710
INFORMATION CONTAINED IN TESTING PROCEDURES...711
CODE KEY TABLE...712
ERROR CODE: [15B0NX]...713
HST OIL FILTER SHOWING CLOGGED CONDITION...713
ERROR CODE: [2G42ZG]...715
LOW ACCUMULATOR OIL PRESSURE INDICATED...715
ERROR CODE: [989F00]...717
TRANSMISSION PROTECTION CAUTION INDICATED...717
ERROR CODE: [989FN1]...718
HST OVERSPEED CONDITION...718
ERROR CODE: [AB00L6]...719
DEFECTIVE BATTERY CHARGING CIRCUIT...719
ERROR CODE: [AB00MA]...721
DEFECTIVE BATTERY CHARGING CIRCUIT...721
ERROR CODE: [B@BAZG]...723
ABNORMAL ENGINE OIL PRESSURE INDICATED...723
ERROR CODE: [B@BCNS]...725
ENGINE COOLANT INDICATING OVERHEAT CONDITION...725
ERROR CODE: [B@BCZK]...727
ABNORMAL COOLANT LEVEL INDICATION...727
ERROR CODE: [B@C7NS]...729
BRAKE COOLING OIL INDICATING OVERHEATING CONDITION...729
ERROR CODE: [B@CRNS]...731
HST OIL SHOWING OVERHEATING CONDITION...731
ERROR CODE: [D5ZHL6]...733
STARTING SWITCH “C” (IGN) INPUT FAILURE INDICATED...733
ERROR CODE: [DAF0KT]...735
CONTROLLER INTERNAL FAILURE)...735
ERROR CODE: [DAJ0KR]...737
HST CONTROLLER COMMUNICATION FAILURE...737
ERROR CODE: [DD15LD]...739
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...739
ERROR CODE: [DD16LD]...741
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...741
ERROR CODE: [DD17LD]...743
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...743
ERROR CODE: [DD18LD]...745
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET...745
ERROR CODE: [DDK3KB]...747
IMPROPER INPUT FOR MULTIPUL SHIFT (FNR) LEVER...747
ERROR CODE: [DDS5L6]...749
DECREASED STEERING OIL PRESSURE...749
ERROR CODE: [DGE2KX]...751
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE...751
ERROR CODE: [DGE3KX]...753
ENGINE COOLANT TEMPERATURE SENSOR OUT OF RANGE...753
ERROR CODE: [DGH1KX]...755
HST OIL SHOWING OVERHEATING CONDITION...755
ERROR CODE: [DGR4KA]...757
BRAKE COOLING OIL INDICATING SHORT CIRCUIT...757
ERROR CODE: [DGR4KX]...759
BRAKE COOLING OIL INDICATING OPEN CIRCUIT...759
ERROR CODE: [DHE4KA]...761
ENGINE OIL PRESSURE INDICATING A SHORT OR OPEN IN THE SYSTEM...761
TROUBLESHOOTING CODE: [MON-1]...763
PARKING BRAKE INDICATOR LAMP DOES NOT WORK...763
TROUBLESHOOTING CODE: [MON-2]...767
BRAKE OIL PRESSURE NOT INDICATING CORRECTLY...767
TROUBLESHOOTING CODE: [MON-3]...769
ENGINE COOLANT SENSOR NOT INDICATING CORRECTLY...769
TROUBLESHOOTING CODE: [MON-4]...771
HST OIL TEMPERATURE NOT INDICATING CORRECTLY...771
TROUBLESHOOTING CODE: [MON-5]...773
FUEL LEVEL GAUGE DOES NOT INDICATE PROPERLY...773
TROUBLESHOOTING CODE: [MON-6]...775
ABNORMAL COOLANT LEVEL INDICATION...775
TROUBLESHOOTING CODE: [MON-7]...777
STEERING OIL PRESSURE NOT READING CORRECTLY...777
TROUBLESHOOTING CODE: [MON-8]...779
EMERGENCY STEERING OIL PRESSURE NOT READING CORRECTLY...779
TROUBLESHOOTING CODE: [MON-9]...781
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...781
TROUBLESHOOTING CODE: [MON-10]...783
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...783
TROUBLESHOOTING CODE: [MON-11]...785
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...785
TROUBLESHOOTING CODE: [MON-12]...787
MONITOR PANEL MODE SELECTOR SWITCH WILL NOT SET CORRECTLY...787
TROUBLESHOOTING CODE: [MON-13]...789
ALARM BUZZER DOES NOT STOP OR REMAINS ON...789
TROUBLESHOOTING CODE: [MON-14]...791
FRONT WINDSHIELD WIPER DOES NOT WORK...791
REAR WINDSHIELD WIPER DOES NOT WORK...793
TROUBLESHOOTING CODE: [MON-15]...795
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION...795
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...799
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...801
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL...801
USER CODE MEMORY RETENTION FUNCTION...801
ELECTRICAL SYSTEM CIRCUIT DIAGRAM...802
FUSE SYSTEM CHECK...808
FUSE PANEL CONNECTION TABLE...808
INFORMATION CONTAINED IN TESTING PROCEDURES...809
CODE: (E-1)...811
ENGINE WILL NOT CRANK...811
CODE: (E-2)...814
THE ENGINE DOES NOT SHUT DOWN...814
CODE: (E-3)...816
COLD START PREHEATER DOES NOT WORK PROPERLY...816
CODE: (E-4)...819
PARKING BRAKE DOES NOT FUNCTION PROPERLY...819
CODE: (E-5)...822
BOOM KICK-OUT FUNCTION NOT WORKING PROPERLY...822
CODE: (E-6)...825
BUCKET LEVER FUNCTION NOT WORKING PROPERLY...825
CODE: (E-7)...828
FLOAT HOLD FUNCTION NOT WORKING PROPERLY...828
CODE: (E-8)...831
FRONT WINDSHIELD WIPER DOES NOT WORK...831
CODE: (E-8)...835
REAR WINDSHIELD WIPER DOES NOT WORK...835
CODE: (E-9)...837
THE WINDOW WASHER DOES NOT WORK...837
CODE: (E-10)...839
HEADLAMPS (LO AND HIGH BEAM) DOES NOT FUNCTION...839
CODE: (E-10)...842
HEADLAMPS (LO BEAM) DO NOT FUNCTION...842
CODE: (E-10)...845
HEADLAMPS (HI BEAM) DO NOT FUNCTION...845
CODE: (E-10)...848
CLEARANCE LAMPS DO NOT FUNCTION...848
CODE: (E-10)...851
TURN SIGNALS DO NOT FUNCTION...851
CODE: (E-10)...854
WORK LAMPS DO NOT FUNCTION...854
CODE: (E-11)...857
HORN DOES NOT SOUND...857
CODE: (E-12)...859
AIR CONDITIONER SYSTEM DOES NOT WORK...859
CODE: (E-12)...862
AIR DOES NOT FLOW FROM SYSTEM AND CANNOT BE ADJUSTED...862
CODE: (E-12)...866
AIR DOES NOT COOL OR TEMPERATURE CANNOT BE ADJUSTED...866
CODE: (E-12)...870
CANNOT SWITCH BETWEEN CIRCULATED AND VENT FUNCTIONS...870
CODE: (E-12)...872
CANNOT SWITCH VENT FUNCTIONS...872
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...875
METHOD OF USING TROUBLESHOOTING CHART...877
FAILURE CODE AND CAUSE TABLE...880
CODE: (H-1)...883
THE MACHINE DOES NOT START...883
CODE: (H-2)...884
THE TRAVEL SPEED IS SLOW...884
CODE: (H-3)...885
THE THRUST FORCE IS WEAK...885
CODE: (H-4)...886
ENGINE STALLS OR ENGINE SPEED DROPS EXCESSIVELY...886
CODE: (H-5)...887
THE GEARS DO NOT CHANGE SPEED RANGE...887
CODE: (H-6)...888
THE STEERING WHEEL DOES NOT TURN...888
CODE: (H-7)...889
STEERING WHEEL MOVEMENT IS HEAVY...889
CODE: (H-8)...890
STEERING WHEEL SHAKES OR HAS JERKY MOVEMENT...890
CODE H-9...890
MACHINE DEVIATES TO ONE SIDE WHEN TRAVELING...890
CODE: (H-10)...891
BRAKES DO NOT WORK OR WORKS POORLY...891
CODE: (H-11)...892
BRAKES IS NOT RELEASING OR DRAGGED...892
CODE: (H-12)...893
THE LIFT ARM DOES NOT RISE OR LOWER...893
CODE: (H-13)...894
LIFT ARM MOVES SLOW OR RISING FORCE IS POOR...894
CODE: (H-14)...895
WHEN RISING LIFT ARM, ARM MOVES SLOWLY AT SPECIFIC HEIGHTS...895
CODE: (H-15)...895
THE LIFT ARM CYLINDER WILL NOT HOLD DOWN THE BUCKET (THE BUCKET RISES)...895
CODE: (H-16)...895
HYDRAULIC DRIFT ON THE LIFT ARM OCCURS OFTEN...895
CODE: (H-17)...895
THE LIFT ARM WOBBLES DURING OPERATION...895
CODE: (H-18)...896
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY...896
CODE: (H-19)...897
THE BUCKET DOES NOT TILT BACK...897
CODE: (H-20)...898
BUCKET MOVES SLOW OR THE TILTING-BACK FORCE IS INSUFFICIENT...898
CODE: (H-21)...899
THE BUCKET OPERATES SLOWLY IN TILTING-BACK...899
CODE: (H-22)...899
BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...899
CODE: (H-23)...899
HYDRAULIC DRIFTS OF THE BUCKET OCCURS OFTEN...899
CODE: (H-24)...899
THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”)...899
CODE: (H-25)...900
WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY...900
CODE: (H-26)...900
CONTROL LEVERS FOR THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY...900
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...901
METHOD OF USING TROUBLESHOOTING CHARTS...902
(S-1) ENGINE STARTING PERFORMANCE IS POOR...906
(S-2) ENGINE HAS STARTING PROBLEMS...908
ENGINE DOES NOT CRANK...908
ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT OF STACK...909
SMOKE COMES OUT OF STACK BUT ENGINE DOES NOT START...910
(S-3) ENGINE DOES NOT RUN SMOOTHLY...911
(S-4) ENGINE STOPS DURING OPERATIONS...912
(S-5) ENGINE SPEED HUNTS...913
(S-6) ENGINE LACKS POWER...914
(S-7) EXHAUST SMOKE IS BLACK...915
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE...916
(S-9) OIL BECOMES CONTAMINATED QUICKLY...917
(S-10) FUEL CONSUMPTION IS EXCESSIVE...918
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR...919
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP...920
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)...921
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)...922
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG...923
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING...924
30 DISASSEMBLY AND ASSEMBLY...925
HOW TO READ THIS MANUAL...928
REMOVAL AND INSTALLATION (DISASSEMBLY AND ASSEMBLY) OF ASSEMBLIES...928
SPECIAL TOOLS...928
REMOVAL AND/OR DISASSEMBLY OF PARTS...928
INSTALLATION AND/OR ASSEMBLY OF PARTS...929
SKETCHES OF SPECIAL TOOLS...929
PRECAUTIONS WHEN PERFORMING OPERATION...930
SPECIAL TOOL LIST...933
SKETCHES OF SPECIAL TOOLS...936
FUEL INJECTION PUMP ASSEMBLY...943
SPECIAL TOOLS...936
REMOVAL...943
INSTALLATION...946
BLEEDING AIR...948
NOZZLE HOLDER ASSEMBLY...949
CYLINDER HEAD ASSEMBLY...951
ENGINE ASSEMBLY...962
REMOVAL...962
INSTALLATION...969
RADIATOR ASSEMBLY...971
REMOVAL...971
INSTALLATION...972
AIR AFTERCOOLER...973
REMOVAL...973
INSTALLATION...974
HYDRAULIC OIL COOLER...975
REMOVAL...975
INSTALLATION...977
COOLING FAN AND FAN MOTOR...978
REMOVAL...978
INSTALLATION...979
FUEL TANK...980
REMOVAL...980
INSTALLATION...982
TRANSFER...983
REMOVAL...983
INSTALLATION...985
TRANSFER ASSEMBLY...986
PARKING BRAKE ASSEMBLY...1011
REMOVAL...1011
INSTALLATION...1012
DISASSEMBLY...1013
FRONT AXLE ASSEMBLY...1020
REMOVAL...1020
INSTALLATION...1022
REAR AXLE ASSEMBLY...1023
REMOVAL...1023
INSTALLATION...1025
AXLE HOUSING ASSEMBLY...1027
DIFFERENTIAL ASSEMBLY...1038
HST PUMP AND 4-GEAR PUMP ASSEMBLY...1070
REMOVAL...1070
INSTALLATION...1073
HST PUMP ASSEMBLY...1074
DISASSEMBLY...1074
ASSEMBLY...1086
HST MOTOR 1 ASSEMBLY...1103
REMOVAL...1103
INSTALLATION...1104
HST MOTOR 2 ASSEMBLY...1105
REMOVAL...1105
INSTALLATION...1106
HST MOTOR ASSEMBLY...1107
DISASSEMBLY...1107
ASSEMBLY...1117
WORK EQUIPMENT CONTROL VALVE ASSEMBLY...1128
REMOVAL...1128
INSTALLATION...1129
TRAVEL DAMPER VALVE ASSEMBLY...1130
REMOVAL...1130
INSTALLATION...1131
HYDRAULIC TANK...1132
REMOVAL...1132
INSTALLATION...1134
WORK EQUIPMENT...1135
REMOVAL...1135
INSTALLATION...1138
PROCEDURE FOR INSTALLING BUCKET LINK AND PIN...1138
PROCEDURE FOR INSTALLING BUCKET HINGE PIN...1139
PROCEDURE FOR INSTALLING BUCKET CYLINDER PIN (ON ROD SIDE)...1139
PROCEDURE FOR INSTALLING BOOM CYLINDER PIN (ON ROD SIDE)...1140
PROCEDURE FOR INSTALLING BOOM PIN (ON FRAME SIDE)...1141
PROCEDURE FOR INSTALLING BUCKET LINK PIN...1141
HYDRAULIC CYLINDER ASSEMBLY...1143
OPERATOR'S CAB ASSEMBLY...1152
OPERATOR'S CAB GLASS...1158
CENTER HINGE PIN...1168
REMOVAL...1168
INSTALLATION...1174
COUNTERWEIGHT...1179
REMOVAL...1179
INSTALLATION...1180
AIR CONDITIONER UNIT ASSEMBLY...1181
AIR CONDITIONER COMPRESSOR ASSEMBLY...1185
MONITOR PANEL...1186
REMOVAL...1186
INSTALLATION...1190
90 OTHERS...1191
HYDRAULIC CIRCUIT DIAGRAM...1192
ELECTRICAL CIRCUIT DIAGRAM...1194
FLOOR HARNESS...1194
MONITOR CIRCUIT...1194
CAB HARNESS...1195
TO FRONT AND BULK HEAD HARNESS...1196
TO REAR AND HST HARNESS...1197
AIR CONDITIONER RELAY HARNESS...1198
TO HST CONTROLLER AND WORK LAMPS...1199
VARIABLE SHIFT CONTROL...1200
SWITCHES...1201
HST AND BULK HEAD HARNESS...1202
GRILL AND ENGINE HARNESS...1203
REAR AND POWER SUPPLY HARNESS...1204
CAB, EMERGENCY STEERING AND MULTI-FUNCTION HARNESS...1205
FRONT HARNESS...1206
REVERSING FAN WIRING DIAGRAM...1207
PROPOSAL FOR MANUAL OR CSS REVISION...1208
SEBM033307 - Wheel Loader WA200-5, WA200PT-5 Shop Manual...1209
COVER...1209
CONTENTS...1210
01 GENERAL...1237
GENERAL ASSEMBLY DRAWINGS...1238
SPECIFICATIONS...1239
WEIGHT TABLE...1243
LIST OF LUBRICANT AND COOLANT...1245
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD...1246
ENGINE MOUNT AND TRANSFER MOUNT...1247
DAMPER ...1248
COOLING SYSTEM ...1249
TRANSFER OIL COOLER...1250
POWER TRAIN...1253
POWER TRAIN SYSTEM DIAGRAM...1254
DRIVE SHAFT(PROPELLER SHAFT)...1256
HST HYDRAULIC PIPING DIAGRAM...1257
HST PUMP...1258
HIGH-PRESSURE RELIEF VALVE...1260
LOW-PRESSURE RELIEF VALVE...1262
HST CHARGE PUMP...1263
SPEED-RELATED VALVE(DA VALVE)...1264
HIGH-PRESSURE CUT-OFF VALVE...1265
HST MOTOR...1266
EP SERVO VALVE...1269
HA SERVO VALVE...1270
FORWARD-REVERSE SHUTTLE VALVE...1271
TRANSFER...1272
CLUTCH SOLENOID VALVE...1283
AXLE...1284
DIFFERENTIAL...1286
LIMITED-SLIP DIFFERENTIAL...1292
FINAL DRIVE...1296
AXLE MOUNTING AND CENTER HINGE PIN...1298
STEERING PIPING...1303
STEERING COLUMN...1304
PRIORITY VALVE...1305
ORBIT-ROLL VALVE...1308
2-WAY RESTRICTOR VALVE...1316
CUSHION VALVE...1317
STEERING CYLINDER...1318
EMERGENCY STEERING PIPING...1320
EMERGENCY STEERING VALVE...1321
BRAKE PIPING...1324
BRAKE VALVE...1325
INCHING VALVE...1329
CHARGE VALVE...1330
ACCUMULATOR (FOR BRAKE)...1334
SLACK ADJUSTER...1335
BRAKE...1337
PARKING BRAKE CONTROL...1340
PARKING BRAKE...1341
HYDRAULIC PIPING...1342
WORK EQUIPMENT LEVEL LINKAGE...1346
HYDRAULIC TANK...1350
4-GEAR PUMP UNIT...1352
ACCUMULATOR (FOR PPC CIRCUIT)...1354
LOCK VALVE...1355
BYPASS VALVE...1356
QUICK COUPLER VALVE...1359
E.C.S.S. VALVE...1360
ACCUMULATOR(FOR E.C.S.S.)...1362
HYDRAULIC PIPING OF COOLING SYSTEM...1363
COOLING FAN MOTOR...1364
WORK EQUIPMENT CONTROL VALVE...1366
WORK EQUIPMENT PPC VALVE...1379
ATTACHMENT PPC VALVE...1387
WORK EQUIPMENT LINKAGE...1391
BUCKET...1395
CONTROL OF BUCKET POSITIONER,BOOM KICK-OUT,AND DUMP SPEED...1397
WORK EQUIPMENT CYLINDER...1411
AIR CONDITIONER...1414
MACHINE MONITORING SYSTEM...1415
MACHINE MONITOR...1424
LIST OF ITEMS DISPLAYED ON MONITOR...1425
ELECTRICAL SYSTEM(HST CONTROLLER SYSTEM)...1451
HST CONTROLLER...1455
ENGINE START CIRCUIT...1456
ENGINE STOP CIRCUIT...1458
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)...1459
PARKING BRAKE CIRCUIT...1460
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...1463
SENSORS...1464
20 TESTING AND ADJUSTING...1470
STANDARD VALUE TABLE FOR ENGINE...1471
STANDARD VALUE TABLE FOR CHASSIS...1472
TESTING AND ADJUSTING...1476
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...1477
MEASURING ENGINE SPEED...1479
MEASURING EXHAUST GAS COLOR...1481
ADJUSTING VALVE CLEARANCE...1482
MEASURING COMPRESSION PRESSURE...1484
MEASURING BLOW-BY PRESSURE...1485
TESTING AND ADJUSTING FUEL INJECTION TIMIING...1486
MEASURING ENGINE OIL PRESSURE...1487
MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL...1488
ADJUSTING ENGINE STOP SOLENOID...1490
ADJUSTING ENGINE SPEED SENSOR...1491
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...1491
MEASURING DIRECTIONAL LEVER...1492
TESTING AND ADJUSTING HST OIL PRESSURE...1493
MEASURING CLUTCH CONTROL PRESSURE...1498
TESTING AND ADJUSTING STEERING WHEEL...1499
TESTING AND ADJUSTING STEERING OIL PRESSURE...1501
BLEEDING AIR FROM STEERING CIRCUIT...1503
TESTING HYDRAULIC FAN...1504
MEASURING BRAKE PEDAL...1505
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...1506
MEASURING BRAKE PERFORMANCE...1507
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...1508
MEASURING BRAKE OIL PRESSURE...1509
MEASURING WEAR OF BRAKE DISC...1511
BLEEDING AIR FORM BRAKE CIRCUIT...1512
MEASURING PARKING BRAKE PERFORMANCE...1513
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE...1514
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...1515
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...1516
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...1517
BLEEDING AIR...1519
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...1520
TESTING AND ADJUSTING BUCKET POSITIONER...1521
TESTING AND ADJUSTING OF BOOM KICK-OUT...1522
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP...1523
PROCEDURE FOR CHECKING DIODE...1524
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...1525
SPECIAL FUNCTIONS OF MACHINE MONITOR...1526
FLOW OF MODES AND FUNCTIONS...1527
PM CLINIC INSPECTION CHART...1545
TROUBLESHOOTING...1547
POINTS TO REMEMBER WHEN TROUBLESHOOTING...1548
SEQUENCE OF EVENTS IN TROUBLESHOOTING...1549
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...1550
CHECK BEFORE TROUBLESHOOTING...1558
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS...1559
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...1560
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...1563
T-ADAPTER TABLE...1585
CONNECTION TYPES AND MOUNTING LOCATIONS...1588
CONNECTION LAYOUT DRAWING...1594
TROUBLESHOOTING OF HST CONTROLLER SYSTEM(HST MODE)...1599
HST CONTROLLER SYSTEM DIAGRAM...1600
BEFORE TROUBLESHOOTING CODE DISPLAY...1602
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...1603
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...1604
ERROR CODE [989F00](HST MOTOR PROTECTION CAUTION(00))...1606
ERROR CODE [DHH1KX](HST OIL PRESSURE SENSOR INPUT SIGNAL OUTISIDE RANGE(KX))...1607
ERROR CODE [DLE2LC](ENGINE REVOLATION SENSOR REVOLUTION SPEED SIGNAL MISMATCH(LC))...1609
ERROR CODE [DW26KZ](MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...1610
ERROR CODE [DX19KZ](MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...1612
ERROR CODE [DX20KZ](CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...1614
[HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))...1616
[HST-2] (TRAVEL SPEED DOES NOT SHIFTED)...1618
[HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED...1621
[HST-4] (TRAVEL SPED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)...1623
[HST-5] (TRAVEL SPEED IS NOT INCREASED)...1625
TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE)...1634
MONITOR SYSTEM CIRCUIT DIAGRAM...1635
BEFORE TROUBLESHOOTING CODE DISPLAY...1639
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...1640
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...1641
FAILURE CODE [15BONX](HST OIL FILTER CLOGGED(NX))...1643
FAILURE CODE [2G42ZG](DECREASED BRAKE OIL PRESSURE(ZG))...1644
FAILURE CODE [989FOO](HST MOTOR PROTECTION CAUTION(00))...1645
FAILURE CODE [989FN1](HST OVERRUNNING (N1))...1646
FAILURE CODE [AB00L6](DEFECTIVE BATTERY CHARGING CIRCUIT (L6))...1647
FAILURE CODE [AB00MA](DEFECTIVE BATTERY CHARGING CIRCUIT (MA))...1648
FAILURE CODE [B@BAZG](DEGREASED ENGINE OIL PRESSURE(ZG))...1649
FAILURE CODE [B@BCNS](ENGINE WATER TEMPERATURE OVERHEATING (NS))...1650
FAILURE CODE [B@BCZK](ALARM INDICATING LOW COOLANT LEVEL (ZK))...1651
FAILURE CODE [B@C7NS](AXLE OIL TEMPERATURE OVERHEATING (NS))...1652
FAILURE CODE [B@CRNS](HST OIL TEMPERATURE OVERHEATING (NS))...1653
FAILURE CODE [D5ZHL6](STARTING SWITCH"C"(IGN"C") INPUT FAILURE (L6))...1654
FAILURE CODE [DAFOKT](CONTROLLER INSIDE FAILURE (KT))...1656
FAILURE CODE [DAJ0KR](HST CONTROLLER COMMUNICATION FAILURE (KR))...1657
FAILURE CODE [DD15LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1) INPUT ERROR(LD))...1659
FAILURE CODE [DD16LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2) INPUT ERROR(LD))...1660
FAILURE CODE [DD17LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3 )INPUT ERROR(LD))...1661
FAILURE CODE [DD18LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4)INPUT ERROR (LD))...1662
FAILURE CODE [DDK3KB](MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB))...1663
FAILURE CODE [DDS5L6](DECREASED STEERING OIL PRESSURE(L6))...1665
FAILURE CODE [DGE2KX](ENGINE WATER TEMPERATURE (HIGH TEMPERATURE)SENSOR SYSTEM FAILURE(KX))...1666
FAILURE CODE [DGE3L6](ENGINE WATER TEMPERATURE(LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6))...1667
FAILURE CODE [DGH1KX](HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))...1668
FAILURE CODE [DGR4KA](AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))...1669
FAILURE CODE [DGR4KX](AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))...1670
FAILURE CODE [DHE4L6](ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))...1671
[MON-1](THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...1672
[MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...1676
[MON-3] (THE ENGINE TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)...1677
[MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)...1678
[MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)...1679
[MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)...1680
[MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...1681
[MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)...1682
[MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH1))...1683
[MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2))...1684
[MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3))...1685
[MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4))...1686
[MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)...1687
[MON-14] THE WIPER DOES NOT FUNCTION...1688
[MON-15] THE LAMPS DO NOT WORK PROPERLY...1688
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...1689
ELECTRICAL SYSTEM DIAGRAM...1690
PARKING BRAKE RELATED DIAGRAM...1693
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM ...1695
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...1696
[E-1] (THE ENGINE DOES NOT START)...1698
[E-2] (THE ENGINE DOES NOT STOP)...1704
[E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...1706
[E-4] (THE PARKING BRAKE (MECHANICAL TYPE)DOES NOT FUNCTION)...1710
[E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...1715
[E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...1718
[E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...1721
[E-8] (THE WIPER DOES NOT FUNCTION)...1722
[E-9] (THE WINDOW WASHER DOES NOT FUNCTION)...1727
[E-10] (LAMPS DO NOT WORK PROPERLY)...1732
[E-11] (THE HORN DOES NOT SOUND)...1735
[E-12] (DEFECTIVE THE AIR CONDITIONER)...1746
[E-13] (DEFECTIVE AIR CONDITIONER)...1748
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)...1756
METHOD OF USING TROUBLESHOOTING CHART...1757
FAILURE CODE AND CAUSE TABLE...1759
H-1 THE MACHINE DOES NOT START...1761
H-2 THE TRAVEL SPEED IS SLOW...1762
H-3 THE THRUSTING FORCE IS WEAK...1763
H-4 ENGINE STALLS WHEN TRAVELLING OR ENGINE SPEED DROPS EXCESSIVELY...1764
H-5 THE GEAR IS NOT SHIFTED...1765
H-6 THE STEERING WHEEL DOES NOT TURN...1766
H-7 THE STEERING WHEEL IS HEAVY...1767
H-8 STEERING WHEEL SHAKES OR JERKS ...1768
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...1768
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...1769
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED...1770
H-12 THE LIFT ARM DOES NOT RISE OR LOWER...1771
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT...1772
H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ...1773
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)...1773
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...1773
H-17 THE LIFT ARM WOBBLES DURING OPERATION...1773
H-18 WHEN THE CONTROL LEVER IS SWITCHED FORM "HOLD" TO "RAISE" ,THE LIFT ARM FALLS TEMPORARILY...1774
H-19 THE BUCKET DOES NOT TILT BACK...1775
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT ...1776
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILITNG-BACK...1777
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...1777
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN...1777
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVES IS SET TO "HOLD")...1778
H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY...1778
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...1778
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES...1779
TROUBLESHOOTING OF ENGINE (S MODE)...1780
METHOD OF USING TROUBLESHOOTING CHARTS...1781
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)...1785
S-2 ENGINE DOES NOT START...1787
(1) ENGINE DOES NOT TURN...1787
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...1788
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS NOT BEING INJECTED)...1789
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)...1790
S-4 ENGINE STOPS DURING OPERATIONS...1791
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)...1792
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...1793
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...1794
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...1795
S-9 OIL BECOMES CONTAMINATED QUICKLY...1796
S-10 FUEL CONSUMPTION IS EXCESSIVE...1797
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...1798
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROPS IN OIL PRESSURE)...1799
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...1800
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...1801
S-15 ABNORMAL NOISE IS MADE...1802
S-16 VIBRATION IS EXCESSIVE...1803
30 DISASSEMBLY AND ASSEMBLY...1804
HOW TO READ THIS MANUAL...1805
PRECAUTIONS WHEN PREFORMING OPERATION...1807
SPECIAL TOOL LIST...1809
SKETCHES OF SPECIAL TOOLS...1812
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...1819
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY...1824
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...1825
REMOVAL AND INSTALLATION OF ENGINE...1833
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...1840
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER ASSEMBLY...1841
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...1843
REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...1845
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...1846
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY...1848
DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY...1851
REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY...1870
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY...1872
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY...1877
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...1878
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY...1881
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY...1889
REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...1915
REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY...1918
REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY...1919
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...1921
REMOVAL AND INSTALLATION OF TRAVEL DAMPER VAVLE ASSEMBLY...1922
REMOVAL AND INSTALLATION OF HYDRAULIC TANK...1924
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...1925
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...1932
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...1940
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...1945
REMOVAL AND INSTALLATION OF CENTER HINGE PIN...1953
REMOVAL AND INSTALLATION OF COUNTERWEIGHT...1960
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...1962
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...1965
REMOVAL AND INSTALLATION OF MONITOR PANEL...1966
90 OTHERS...1969
HYDRAULIC CIRCUIT DIAGRAM ...1970
WA200-5...1970
HYDRAULIC CIRCUIT DIAGRAM ...1971
WA200PT-5...1971
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CAB)...1972
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CAB)...1973
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CAB)...1974
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CAB)...1975
ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CAB)...1976
ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CAB)...1977
ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CAB)...1978
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...1979
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...1980
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...1981
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...1982
ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CANOPY)...1983
ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CANOPY)...1984
ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CANOPY)...1985
SEBM033309 - Wheel Loader WA200-5, WA200PT-5 Shop Manual...1986
COVER...1986
CONTENTS...1987
LIST OF REVISED PAGES...1988
SAFETY...1994
SAFETY NOTICE...1994
FOREWORD...1996
GENERAL...1996
HOW TO READ THE SHOP MANUAL...1997
HOISTING INSTRUCTIONS...1998
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...1999
COATING MATERIALS...2001
STANDARD TIGHTENING TORQUE...2003
ELECTRIC WIRE CODE...2006
CONVERSION TABLE...2007
UNITS...2013
01 GENERAL...2014
GENERAL ASSEMBLY DRAWINGS...2015
SPECIFICATIONS...2016
WEIGHT TABLE...2020
LIST OF LUBRICANT AND COOLANT...2022
10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD...2024
ENGINE MOUNT AND TRANSFER MOUNT...2025
DAMPER ...2026
COOLING SYSTEM ...2027
TRANSFER OIL COOLER...2028
POWER TRAIN...2031
POWER TRAIN SYSTEM DIAGRAM...2033
DRIVE SHAFT(PROPELLER SHAFT)...2035
HST HYDRAULIC PIPING DIAGRAM...2036
HST PUMP...2037
HIGH-PRESSURE RELIEF VALVE...2039
LOW-PRESSURE RELIEF VALVE...2041
HST CHARGE PUMP...2042
SPEED-RELATED VALVE(DA VALVE)...2043
HIGH-PRESSURE CUT-OFF VALVE...2044
HST MOTOR...2045
EP SERVO VALVE...2048
HA SERVO VALVE...2049
FORWARD-REVERSE SHUTTLE VALVE...2050
TRANSFER...2051
CLUTCH SOLENOID VALVE...2062
AXLE...2063
DIFFERENTIAL...2065
LIMITED-SLIP DIFFERENTIAL...2071
FINAL DRIVE...2075
AXLE MOUNTING AND CENTER HINGE PIN...2077
STEERING PIPING...2082
STEERING COLUMN...2083
PRIORITY VALVE...2084
ORBIT-ROLL VALVE...2087
2-WAY RESTRICTOR VALVE...2095
CUSHION VALVE...2096
STEERING CYLINDER...2097
EMERGENCY STEERING PIPING...2099
EMERGENCY STEERING VALVE...2100
BRAKE PIPING...2103
BRAKE VALVE...2104
INCHING VALVE...2108
CHARGE VALVE...2109
ACCUMULATOR (FOR BRAKE)...2113
SLACK ADJUSTER...2114
BRAKE...2117
PARKING BRAKE CONTROL...2120
PARKING BRAKE...2121
HYDRAULIC PIPING...2123
WORK EQUIPMENT LEVEL LINKAGE...2127
HYDRAULIC TANK...2132
4-GEAR PUMP UNIT...2135
ACCUMULATOR (FOR PPC CIRCUIT)...2137
LOCK VALVE...2138
BYPASS VALVE...2139
QUICK COUPLER VALVE...2142
E.C.S.S. VALVE...2143
ACCUMULATOR(FOR E.C.S.S.)...2145
HYDRAULIC PIPING OF COOLING SYSTEM...2146
COOLING FAN MOTOR...2147
WORK EQUIPMENT CONTROL VALVE...2149
WORK EQUIPMENT PPC VALVE...2162
ATTACHMENT PPC VALVE...2171
WORK EQUIPMENT LINKAGE...2175
BUCKET...2179
CONTROL OF BUCKET POSITIONER,BOOM KICK-OUT,AND DUMP SPEED...2182
WORK EQUIPMENT CYLINDER...2196
AIR CONDITIONER...2199
MACHINE MONITORING SYSTEM...2201
MACHINE MONITOR...2210
LIST OF ITEMS DISPLAYED ON MONITOR...2211
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...2237
HST CONTROLLER...2241
KOMTRAX SYSTEM...2242
ENGINE START CIRCUIT...2244
ENGINE STOP CIRCUIT...2246
PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)...2247
PARKING BRAKE CIRCUIT...2248
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM...2251
SENSORS...2252
20 TESTING AND ADJUSTING...2258
STANDARD VALUE TABLE FOR ENGINE...2259
STANDARD VALUE TABLE FOR CHASSIS...2260
TESTING AND ADJUSTING...2264
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...2265
MEASURING ENGINE SPEED...2267
MEASURING EXHAUST GAS COLOR...2269
ADJUSTING VALVE CLEARANCE...2270
MEASURING COMPRESSION PRESSURE...2272
MEASURING BLOW-BY PRESSURE...2273
TESTING AND ADJUSTING FUEL INJECTION TIMIING...2274
MEASURING ENGINE OIL PRESSURE...2275
MEASURING,TESTING OPERATING FORCE OF ACCELERATOR PEDAL...2276
ADJUSTING ENGINE STOP SOLENOID...2278
ADJUSTING ENGINE SPEED SENSOR...2279
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...2279
MEASURING DIRECTIONAL LEVER...2280
TESTING AND ADJUSTING HST OIL PRESSURE...2281
MEASURING CLUTCH CONTROL PRESSURE...2286
TESTING AND ADJUSTING STEERING WHEEL...2287
TESTING AND ADJUSTING STEERING OIL PRESSURE...2289
BLEEDING AIR FROM STEERING CIRCUIT...2291
TESTING HYDRAULIC FAN...2292
MEASURING BRAKE PEDAL...2293
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE...2294
MEASURING BRAKE PERFORMANCE...2295
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...2296
MEASURING BRAKE OIL PRESSURE...2297
MEASURING WEAR OF BRAKE DISC...2299
BLEEDING AIR FORM BRAKE CIRCUIT...2300
MEASURING PARKING BRAKE PERFORMANCE...2301
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE...2302
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER...2303
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...2304
TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...2305
BLEEDING AIR...2307
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...2308
TESTING AND ADJUSTING BUCKET POSITIONER...2309
TESTING AND ADJUSTING OF BOOM KICK-OUT...2310
CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP...2311
PROCEDURE FOR CHECKING DIODE...2312
METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...2313
STARTING KOMTRAX TERMINAL OPERATIONS...2314
INDICATOR LAMPS OF KOMTRAX TERMINAL...2318
SPECIAL FUNCTIONS OF MACHINE MONITOR...2322
FLOW OF MODES AND FUNCTIONS...2323
PM CLINIC INSPECTION CHART...2341
TROUBLESHOOTING...2344
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2345
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2346
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...2347
CHECK BEFORE TROUBLESHOOTING...2355
CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS...2356
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...2357
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2361
T-ADAPTER TABLE...2383
CONNECTION TYPES AND MOUNTING LOCATIONS...2386
CONNECTION LAYOUT DRAWING...2393
TROUBLESHOOTING OF HST CONTROLLER SYSTEM(HST MODE)...2398
HST CONTROLLER SYSTEM DIAGRAM...2399
BEFORE TROUBLESHOOTING CODE DISPLAY...2401
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...2402
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...2403
ERROR CODE [989F00](HST MOTOR PROTECTION CAUTION(00))...2405
ERROR CODE [DHH1KX](HST OIL PRESSURE SENSOR INPUT SIGNAL OUTISIDE RANGE(KX))...2406
ERROR CODE [DLE2LC](ENGINE REVOLATION SENSOR REVOLUTION SPEED SIGNAL MISMATCH(LC))...2408
ERROR CODE [DW26KZ](MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...2409
ERROR CODE [DX19KZ](MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...2411
ERROR CODE [DX20KZ](CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...2413
[HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))...2415
[HST-2] (TRAVEL SPEED DOES NOT SHIFTED)...2417
[HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED...2420
[HST-4] (TRAVEL SPED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)...2422
[HST-5] (TRAVEL SPEED IS NOT INCREASED)...2424
TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE)...2434
MONITOR SYSTEM CIRCUIT DIAGRAM...2435
BEFORE TROUBLESHOOTING CODE DISPLAY...2439
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM...2440
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...2441
FAILURE CODE [15BONX](HST OIL FILTER CLOGGED(NX))...2443
FAILURE CODE [2G42ZG](DECREASED BRAKE OIL PRESSURE(ZG))...2444
FAILURE CODE [989FOO](HST MOTOR PROTECTION CAUTION(00))...2445
FAILURE CODE [989FN1](HST OVERRUNNING (N1))...2446
FAILURE CODE [AB00L6](DEFECTIVE BATTERY CHARGING CIRCUIT (L6))...2447
FAILURE CODE [AB00MA](DEFECTIVE BATTERY CHARGING CIRCUIT (MA))...2448
FAILURE CODE [B@BAZG](DEGREASED ENGINE OIL PRESSURE(ZG))...2449
FAILURE CODE [B@BCNS](ENGINE WATER TEMPERATURE OVERHEATING (NS))...2450
FAILURE CODE [B@BCZK](ALARM INDICATING LOW COOLANT LEVEL (ZK))...2451
FAILURE CODE [B@C7NS](AXLE OIL TEMPERATURE OVERHEATING (NS))...2452
FAILURE CODE [B@CRNS](HST OIL TEMPERATURE OVERHEATING (NS))...2453
FAILURE CODE [D5ZHL6](STARTING SWITCH"C"(IGN"C") INPUT FAILURE (L6))...2455
FAILURE CODE [DAFOKT](CONTROLLER INSIDE FAILURE (KT))...2457
FAILURE CODE [DAJ0KR](HST CONTROLLER COMMUNICATION FAILURE (KR))...2459
FAILURE CODE [DD15LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH 1) INPUT ERROR(LD))...2461
FAILURE CODE [DD16LD](MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2) INPUT ERROR(LD))...2462
FAILURE CODE [DD17LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3 )INPUT ERROR(LD))...2463
FAILURE CODE [DD18LD](MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4)INPUT ERROR (LD))...2464
FAILURE CODE [DDK3KB](MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB))...2465
FAILURE CODE [DDS5L6](DECREASED STEERING OIL PRESSURE(L6))...2467
FAILURE CODE [DGE2KX](ENGINE WATER TEMPERATURE (HIGH TEMPERATURE)SENSOR SYSTEM FAILURE(KX))...2468
FAILURE CODE [DGE3L6](ENGINE WATER TEMPERATURE(LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6))...2469
FAILURE CODE [DGH1KX](HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))...2470
FAILURE CODE [DGR4KA](AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))...2471
FAILURE CODE [DGR4KX](AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))...2472
FAILURE CODE [DHE4L6](ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))...2473
[MON-1](THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...2475
[MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...2479
[MON-3] (THE ENGINE TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.)...2480
[MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.)...2481
[MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)...2482
[MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)...2483
[MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)...2484
[MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)...2485
[MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [■](PANEL SWITCH1))...2486
[MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [◇](PANEL SWITCH 2))...2487
[MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<](PANEL SWITCH 3))...2488
[MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>](PANEL SWITCH 4))...2489
[MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)...2490
[MON-14] THE WIPER DOES NOT FUNCTION...2491
[MON-15] THE LAMPS DO NOT WORK PROPERLY...2491
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...2492
ELECTRICAL SYSTEM DIAGRAM...2493
PARKING BRAKE RELATED DIAGRAM...2497
BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM ...2499
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...2501
[E-1] (THE ENGINE DOES NOT START)...2503
[E-2] (THE ENGINE DOES NOT STOP)...2509
[E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)...2511
[E-4] (THE PARKING BRAKE (MECHANICAL TYPE)DOES NOT FUNCTION)...2515
[E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...2522
[E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...2525
[E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...2528
[E-8] (THE WIPER DOES NOT FUNCTION)...2529
[E-9] (THE WINDOW WASHER DOES NOT FUNCTION)...2535
[E-10] (LAMPS DO NOT WORK PROPERLY)...2541
[E-11] (THE HORN DOES NOT SOUND)...2544
[E-12] (DEFECTIVE THE AIR CONDITIONER)...2555
[E-13] (DEFECTIVE AIR CONDITIONER)...2557
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)...2566
METHOD OF USING TROUBLESHOOTING CHART...2567
FAILURE CODE AND CAUSE TABLE...2569
H-1 THE MACHINE DOES NOT START...2571
H-2 THE TRAVEL SPEED IS SLOW...2572
H-3 THE THRUSTING FORCE IS WEAK...2573
H-4 ENGINE STALLS WHEN TRAVELLING OR ENGINE SPEED DROPS EXCESSIVELY...2574
H-5 THE GEAR IS NOT SHIFTED...2575
H-6 THE STEERING WHEEL DOES NOT TURN...2576
H-7 THE STEERING WHEEL IS HEAVY...2577
H-8 STEERING WHEEL SHAKES OR JERKS ...2578
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...2578
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...2579
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED...2580
H-12 THE LIFT ARM DOES NOT RISE OR LOWER...2582
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT...2583
H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ...2584
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)...2584
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...2584
H-17 THE LIFT ARM WOBBLES DURING OPERATION...2584
H-18 WHEN THE CONTROL LEVER IS SWITCHED FORM "HOLD" TO "RAISE" ,THE LIFT ARM FALLS TEMPORARILY...2585
H-19 THE BUCKET DOES NOT TILT BACK...2586
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT ...2587
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILITNG-BACK...2588
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET...2588
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN...2588
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVES IS SET TO "HOLD")...2589
H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPORARILY...2589
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...2589
H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES...2590
TROUBLESHOOTING OF ENGINE (S MODE)...2592
METHOD OF USING TROUBLESHOOTING CHARTS...2593
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)...2597
S-2 ENGINE DOES NOT START...2599
(1) ENGINE DOES NOT TURN...2599
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...2600
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS NOT BEING INJECTED)...2601
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)...2602
S-4 ENGINE STOPS DURING OPERATIONS...2603
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)...2604
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...2605
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...2606
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...2607
S-9 OIL BECOMES CONTAMINATED QUICKLY...2608
S-10 FUEL CONSUMPTION IS EXCESSIVE...2609
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...2610
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROPS IN OIL PRESSURE)...2611
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...2612
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...2613
S-15 ABNORMAL NOISE IS MADE...2614
S-16 VIBRATION IS EXCESSIVE...2615
30 DISASSEMBLY AND ASSEMBLY...2616
HOW TO READ THIS MANUAL...2617
PRECAUTIONS WHEN PREFORMING OPERATION...2619
SPECIAL TOOL LIST...2621
SKETCHES OF SPECIAL TOOLS...2624
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY...2631
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY...2636
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...2637
REMOVAL AND INSTALLATION OF ENGINE...2645
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...2652
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER ASSEMBLY...2653
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...2655
REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY...2657
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...2658
REMOVAL AND INSTALLATION OF TRANSFER ASSEMBLY...2660
DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY...2663
REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY...2682
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY...2684
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY...2689
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...2690
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY...2693
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY...2701
REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...2728
REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY...2731
REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY...2732
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...2734
REMOVAL AND INSTALLATION OF TRAVEL DAMPER VAVLE ASSEMBLY...2735
REMOVAL AND INSTALLATION OF HYDRAULIC TANK...2737
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY...2738
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...2745
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...2753
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...2758
REMOVAL AND INSTALLATION OF CENTER HINGE PIN...2766
REMOVAL AND INSTALLATION OF COUNTERWEIGHT...2773
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...2775
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY...2778
REMOVAL AND INSTALLATION OF MONITOR PANEL...2779
90 OTHERS...2782
HYDRAULIC CIRCUIT DIAGRAM WA200-5...2784
HYDRAULIC CIRCUIT DIAGRAM WA200PT-5...2785
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CAB)...2786
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CAB)...2787
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CAB)...2788
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CAB)...2789
ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CAB)...2790
ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CAB)...2791
ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CAB)...2792
ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...2793
ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...2794
ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...2795
ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4)(MACHINES EQUIPPED WITH ROPS CANOPY)...2796
ELECTRICAL CIRCUIT DIAGRAM 2/4(MACHINES EQUIPPED WITH ROPS CANOPY)...2797
ELECTRICAL CIRCUIT DIAGRAM 3/4(MACHINES EQUIPPED WITH ROPS CANOPY)...2798
ELECTRICAL CIRCUIT DIAGRAM 4/4(MACHINES EQUIPPED WITH ROPS CANOPY)...2799
TEN00080-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual...2800
COVER...2800
FOREWORD...2801
FOREWORD...2802
SAFETY INFORMATION...2805
INTRODUCTION...2807
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...2807
NECESSARY INFORMATION...2808
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...2808
ENGINE SERIAL NO. PLATE...2808
POSITION OF SERVICE METER...2809
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...2809
CONTENTS...2810
SAFETY...2813
SAFETY...2814
SAFETY LABELS...2817
LOCATION OF SAFETY LABELS...2817
SAFETY LABELS...2818
GENERAL PRECAUTIONS...2823
SAFETY RULES...2823
IF ABNORMALITIES ARE FOUND...2823
CLOTHING AND PERSONAL PROTECTIVE ITEMS...2823
FIRE EXTINGUISHER AND FIRST AID KIT...2823
SAFETY FEATURES...2823
KEEP MACHINE CLEAN...2824
INSIDE OPERATOR'S COMPARTMENT...2824
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...2824
HANDRAILS AND STEPS...2825
MOUNTING AND DISMOUNTING...2826
NO PEOPLE ON ATTACHMENTS...2826
DO NOT GET CAUGHT IN ARTICULATED PORTION...2826
PREVENTION OF BURNS...2826
FIRE PREVENTION...2827
ACTION IF FIRE OCCURS...2828
WINDOW WASHER LIQUID...2828
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...2828
PRECAUTIONS FOR ATTACHMENTS, OPTIONS...2828
UNAUTHORIZED MODIFICATION...2828
SAFETY AT WORKSITE...2829
WORKING ON LOOSE GROUND...2829
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...2829
ENSURE GOOD VISIBILITY...2830
VENTILATION FOR ENCLOSED AREAS...2830
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...2830
EMERGENCY EXIT FROM OPERATOR'S CAB...2830
BE CAREFUL ABOUT ASBESTOS DUST...2831
PRECAUTIONS FOR OPERATION...2832
STARTING ENGINE...2832
CHECKS BEFORE STARTING ENGINE...2832
PRECAUTIONS WHEN STARTING...2832
PRECAUTIONS IN COLD AREAS...2833
OPERATION...2834
CHECKS BEFORE OPERATION...2834
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...2834
PRECAUTIONS WHEN TRAVELING...2835
TRAVELING ON SLOPES...2836
PROHIBITED OPERATIONS...2837
PRECAUTIONS WHEN OPERATING...2837
METHODS OF USING BRAKE...2838
OPERATE CAREFULLY ON SNOW...2838
PARKING MACHINE...2839
TRANSPORTATION...2840
LOADING AND UNLOADING...2840
SHIPPING...2840
BATTERY...2841
BATTERY HAZARD PREVENTION...2841
STARTING WITH BOOSTER CABLES...2842
TOWING...2843
WHEN TOWING...2843
PRECAUTIONS FOR MAINTENANCE...2844
WARNING TAG...2844
KEEP WORK PLACE CLEAN AND TIDY...2844
APPOINT LEADER WHEN WORKING WITH OTHERS...2844
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...2845
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...2846
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...2846
PROPER TOOLS...2847
ACCUMULATOR...2847
PERSONNEL...2847
ATTACHMENTS...2847
WORK UNDER THE MACHINE...2848
NOISE...2848
PRECAUTIONS WHEN USING HAMMER...2848
REPAIR WELDING...2848
REMOVING BATTERY TERMINAL...2848
PRECAUTIONS WITH HIGH-PRESSURE OIL...2849
HANDLING HIGH-PRESSURE HOSES...2849
WASTE MATERIALS...2849
MAINTENANCE OF AIR CONDITIONER...2849
COMPRESSED AIR...2850
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2850
PRECAUTIONS WITH TIRES...2851
HANDLING TIRES...2851
PRECAUTIONS WHEN STORING TIRES...2851
OPERATION...2852
GENERAL VIEW...2853
GENERAL VIEW OF MACHINE...2853
GENERAL VIEW OF CONTROLS AND GAUGES...2854
EXPLANATION OF COMPONENTS...2856
MACHINE MONITOR...2856
SWITCHES...2882
CONTROL LEVERS, PEDALS...2891
STEERING TILT LOCK LEVER...2895
CAP AND COVER WITH LOCK...2895
FRAME LOCK BAR...2896
TOWING PIN...2897
GREASE PUMP...2897
CAB DOOR INNER LOCK...2897
CAB DOOR OPEN LOCK...2898
CAB WINDOW OPEN LOCK CANCEL KNOB...2898
FUSE...2898
SLOW BLOW FUSE...2900
POWER OUTLET...2900
STORAGE BOX...2900
AM/FM RADIO-CASSETTE STEREO...2901
AIR CONDITIONER...2909
HANDLING CAB WIPER...2914
OPERATION...2915
CHECK BEFORE STARTING ENGINE, ADJUST...2915
STARTING ENGINE...2930
OPERATIONS AND CHECKS AFTER STARTING ENGINE...2932
STOPPING ENGINE...2934
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...2935
TURNING...2940
OPERATION OF WORK EQUIPMENT...2942
WORK POSSIBLE USING WHEEL LOADER...2944
PRECAUTIONS FOR OPERATION...2949
ADJUSTING WORK EQUIPMENT POSTURE...2951
PARKING MACHINE...2953
CHECKS AFTER COMPLETION OF OPERATION...2955
LOCKING...2955
HANDLING THE TIRES...2956
TRANSPORTATION...2958
TRANSPORTATION PROCEDURE...2958
LOADING, UNLOADING WORK WITH TRAILERS...2958
LIFTING MACHINE...2962
COLD WEATHER OPERATION...2964
PRECAUTIONS FOR LOW TEMPERATURE...2964
PRECAUTIONS AFTER COMPLETION OF WORK...2965
AFTER COLD WEATHER...2965
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...2966
LONG-TERM STORAGE...2967
BEFORE STORAGE...2967
DURING STORAGE...2967
AFTER STORAGE...2967
TROUBLESHOOTING...2968
WHEN MACHINE RUNS OUT OF FUEL...2968
METHOD OF TOWING MACHINE...2968
IF BATTERY IS DISCHARGED...2970
OTHER TROUBLE...2973
MAINTENANCE...2978
GUIDES TO MAINTENANCE...2979
OUTLINES OF SERVICE...2981
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...2981
OUTLINE OF ELECTRIC SYSTEM...2984
WEAR PARTS...2985
WEAR PARTS LIST...2985
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...2986
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...2987
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...2988
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...2989
TORQUE LIST...2989
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...2990
MAINTENANCE SCHEDULE CHART...2991
MAINTENANCE SCHEDULE CHART...2991
SERVICE PROCEDURE...2993
INITIAL 250 HOURS SERVICE...2993
WHEN REQUIRED...2994
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...2994
CLEAN INSIDE OF COOLING SYSTEM...2997
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...3000
CHECK AXLE OIL LEVEL, ADD OIL...3001
CLEAN AXLE CASE BREATHER...3002
CLEAN AIR CONDITIONER CONDENSER...3003
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...3003
CLEAN RADIATOR FINS AND COOLER FINS...3004
CLEAN TRANSFER OIL COOLER FINS...3004
CHECK ELECTRICAL INTAKE AIR HEATER...3004
TURN, REPLACE BOLT-ON CUTTING EDGE...3005
REPLACE BUCKET TEETH...3006
CHECK AIR CONDITIONER...3008
REPLACE SLOW BLOW FUSE...3009
CHECKING FUNCTION OF ACCUMULATOR...3010
SELECTION AND INSPECTION OF TIRES...3011
CHECK BEFORE STARTING...3013
EVERY 50 HOURS SERVICE...3014
DRAIN WATER, SEDIMENT FROM FUEL TANK...3014
EVERY 100 HOURS SERVICE...3015
LUBRICATE REAR AXLE PIVOT PIN...3015
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...3015
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...3016
EVERY 250 HOURS SERVICE...3017
CHECK BATTERY ELECTROLYTE LEVEL...3017
CHECK PARKING BRAKE...3019
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...3019
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...3020
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...3021
CHECKING FUNCTION OF ACCUMULATOR...3021
LUBRICATING...3022
EVERY 500 HOURS SERVICE...3023
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...3023
REPLACE FUEL FILTER CARTRIDGE...3024
CLEAN WATER SEPARATOR STRAINER...3025
EVERY 1000 HOURS SERVICE...3026
CHANGE OIL IN TRANSFER CASE...3026
CLEAN TRANSFER CASE BREATHER...3027
REPLACE HST OIL FILTER ELEMENT...3028
LUBRICATING...3029
CHECK TIGHTENING PARTS OF TURBOCHARGER...3029
CHECK PLAY OF TURBOCHARGER ROTOR...3029
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...3029
EVERY 2000 HOURS SERVICE...3030
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...3030
REPLACE HYDRAULIC TANK BREATHER ELEMENT...3031
CHANGE AXLE OIL...3032
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...3032
CLEAN BRAKE CIRCUIT STRAINER...3033
CHECK BRAKE DISC WEAR...3034
CHECKING FUNCTION OF ACCUMULATOR...3035
CHECK ALTERNATOR, STARTING MOTOR...3035
CHECK ENGINE VALVE CLEARANCE, ADJUST...3035
CLEAN AND CHECK TURBOCHARGER...3035
CHECK VIBRATION DAMPER...3035
EVERY 4000 HOURS SERVICE...3036
LUBRICATING...3036
CHECK WATER PUMP...3036
SPECIFICATIONS...3037
SPECIFICATIONS...3038
ATTACHMENTS, OPTIONS...3040
SELECTING BUCKET AND TIRES...3041
INDEX...3042
TEN00082-00 - Wheel Loader GALEO WA200PTL-5 Operation & Maintenance Manual...3045
COVER...3045
FOREWORD...3046
FOREWORD...3047
SAFETY INFORMATION...3050
INTRODUCTION...3052
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE...3052
NECESSARY INFORMATION...3053
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...3053
ENGINE SERIAL NO. PLATE...3053
POSITION OF SERVICE METER...3054
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...3054
CONTENTS...3055
SAFETY...3058
SAFETY...3059
SAFETY LABELS...3062
LOCATION OF SAFETY LABELS...3062
SAFETY LABELS...3063
GENERAL PRECAUTIONS...3068
SAFETY RULES...3068
IF ABNORMALITIES ARE FOUND...3068
CLOTHING AND PERSONAL PROTECTIVE ITEMS...3068
FIRE EXTINGUISHER AND FIRST AID KIT...3068
SAFETY FEATURES...3068
KEEP MACHINE CLEAN...3069
INSIDE OPERATOR'S COMPARTMENT...3069
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...3069
HANDRAILS AND STEPS...3070
MOUNTING AND DISMOUNTING...3071
NO PEOPLE ON ATTACHMENTS ...3071
DO NOT GET CAUGHT IN ARTICULATED PORTION...3071
PREVENTION OF BURNS...3071
FIRE PREVENTION...3072
ACTION IF FIRE OCCURS...3073
WINDOW WASHER LIQUID...3073
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...3073
PRECAUTIONS FOR ATTACHMENTS, OPIONS...3073
UNAUTHORIZED MODIFICATION...3073
SAFETY AT WORKSITE...3074
WORKING ON LOOSE GROUND...3074
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...3074
ENSURE GOOD VISIBILITY...3075
VENTILATION FOR ENCLOSED AREAS...3075
CHECKING SIGNALMAN'S SIGNALS AND SIGNS...3075
EMERGENCY EXIT FROM OPERATOR'S CAB...3075
BE CAREFUL ABOUT ASBESTOS DUST...3076
PRECAUTIONS FOR OPERATION...3077
STARTING ENGINE...3077
CHECKS BEFORE STARTING ENGINE...3077
PRECAUTIONS WHEN STARTING...3077
PRECAUTIONS IN COLD AREAS...3078
OPERATION...3079
CHECKS BEFORE OPERATION...3079
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...3079
PRECAUTIONS WHEN TRAVELING...3080
TRAVELING ON SLOPES...3081
PROHIBITED OPERATIONS...3082
PRECAUTIONS WHEN OPERATING...3082
METHODS OF USING BRAKE...3083
OPERATE CAREFULLY ON SNOW...3083
PARKING MACHINE...3084
TRANSPORTATION...3085
LOADING AND UNLOADING...3085
SHIPPING...3085
BATTERY...3086
BATTERY HAZARD PREVENTION...3086
STARTING WITH BOOSTER CABLES...3087
TOWING...3088
WHEN TOWING...3088
PRECAUTIONS FOR MAINTENANCE...3089
WARNING TAG...3089
KEEP WORK PLACE CLEAN AND TIDY...3089
APPOINT LEADER WHEN WORKING WITH OTHERS...3089
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...3090
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...3091
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...3091
PROPER TOOLS...3092
ACCUMULATOR...3092
PERSONNEL...3092
ATTACHMENTS...3092
WORK UNDER THE MACHINE...3093
NOISE...3093
PRECAUTIONS WHEN USING HAMMER...3093
REPAIR WELDING...3093
REMOVING BATTERY TERMINAL...3093
PRECAUTIONS WITH HIGH-PRESSURE OIL...3094
HANDLING HIGH-PRESSURE HOSES...3094
WASTE MATERIALS...3094
MAINTENANCE OF AIR CONDITIONER...3094
COMPRESSED AIR...3095
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...3095
PRECAUTIONS WITH TIRES...3096
HANDLING TIRES...3096
PRECAUTIONS WHEN STORING TIRES...3096
OPERATION...3097
GENERAL VIEW...3098
GENERAL VIEW OF MACHINE...3098
GENERAL VIEW OF CONTROLS AND GAUGES...3099
EXPLANATION OF COMPONENTS...3101
MACHINE MONITOR...3101
SWITCHES...3127
CONTROL LEVERS, PEDALS...3136
STEERING TILT LOCK LEVER...3140
CAP AND COVER WITH LOCK...3140
FRAME LOCK BAR...3141
TOWING PIN...3142
GREASE PUMP...3142
CAB DOOR INNER LOCK...3142
CAB DOOR OPEN LOCK...3143
CAB WINDOW OPEN LOCK CANCEL KNOB...3143
FUSE...3143
SLOW BLOW FUSE...3145
POWER OUTLET...3145
STORAGE BOX...3145
AM/FM RADIO-CASSETTE STEREO...3146
AIR CONDITIONER...3154
HANDLING CAB WIPER...3159
OPERATION...3160
CHECK BEFORE STARTING ENGINE, ADJUST...3160
STARTING ENGINE...3175
OPERATIONS AND CHECKS AFTER STARTING ENGINE...3177
STOPPING ENGINE...3179
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE...3180
TURNING...3185
OPERATION OF WORK EQUIPMENT...3187
HANDLING HYDRAULIC QUICK COUPLER...3189
WORK POSSIBLE USING WHEEL LOADER...3193
PRECAUTIONS FOR OPERATION...3198
ADJUSTING WORK EQUIPMENT POSTURE...3200
PARKING MACHINE...3204
CHECKS AFTER COMPLETION OF OPERATION...3206
LOCKING...3206
HANDLING THE TIRES...3207
TRANSPORTATION...3209
TRANSPORTATION PROCEDURE...3209
LOADING, UNLOADING WORK WITH TRAILERS...3209
LIFTING MACHINE...3213
COLD WEATHER OPERATION...3215
PRECAUTIONS FOR LOW TEMPERATURE...3215
PRECAUTIONS AFTER COMPLETION OF WORK...3216
AFTER COLD WEATHER...3216
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...3217
LONG-TERM STORAGE...3218
BEFORE STORAGE...3218
DURING STORAGE...3218
AFTER STORAGE...3218
TROUBLESHOOTING...3219
WHEN MACHINE RUNS OUT OF FUEL...3219
METHOD OF TOWING MACHINE...3219
IF BATTERY IS DISCHARGED...3221
OTHER TROUBLE...3224
MAINTENANCE...3229
GUIDES TO MAINTENANCE...3230
OUTLINES OF SERVICE...3232
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...3232
OUTLINE OF ELECTRIC SYSTEM...3235
WEAR PARTS...3236
WEAR PARTS LIST...3236
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...3237
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...3238
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...3239
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...3240
TORQUE LIST...3240
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...3241
MAINTENANCE SCHEDULE CHART...3242
MAINTENANCE SCHEDULE CHART...3242
SERVICE PROCEDURE...3244
INITIAL 250 HOURS SERVICE...3244
WHEN REQUIRED...3245
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT...3245
CLEAN INSIDE OF COOLING SYSTEM...3248
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL...3251
CHECK AXLE OIL LEVEL, ADD OIL...3252
CLEAN AXLE CASE BREATHER...3253
CLEAN AIR CONDITIONER CONDENSER...3254
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...3254
CLEAN RADIATOR FINS AND COOLER FINS...3255
CLEAN TRANSFER OIL COOLER FINS...3255
CHECK ELECTRICAL INTAKE AIR HEATER...3255
TURN, REPLACE BOLT-ON CUTTING EDGE...3256
REPLACE BUCKET TEETH...3257
CHECK AIR CONDITIONER...3258
REPLACE SLOW BLOW FUSE...3259
CHECKING FUNCTION OF ACCUMULATOR...3260
SELECTION AND INSPECTION OF TIRES...3261
CHECK BEFORE STARTING...3263
EVERY 50 HOURS SERVICE...3264
DRAIN WATER, SEDIMENT FROM FUEL TANK...3264
EVERY 100 HOURS SERVICE...3265
LUBRICATE REAR AXLE PIVOT PIN...3265
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...3265
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...3266
EVERY 250 HOURS SERVICE...3267
CHECK BATTERY ELECTROLYTE LEVEL...3267
CHECK PARKING BRAKE...3269
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...3269
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN...3270
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...3271
CHECKING FUNCTION OF ACCUMULATOR...3271
LUBRICATING...3272
EVERY 500 HOURS SERVICE...3273
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...3273
REPLACE FUEL FILTER CARTRIDGE...3274
CLEAN WATER SEPARATOR STRAINER...3275
EVERY 1000 HOURS SERVICE...3276
CHANGE OIL IN TRANSFER CASE...3276
CLEAN TRANSFER CASE BREATHER...3277
REPLACE HST OIL FILTER ELEMENT...3278
LUBRICATING...3279
CHECK TIGHTENING PARTS OF TURBOCHARGER...3279
CHECK PLAY OF TURBOCHARGER ROTOR...3279
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...3279
EVERY 2000 HOURS SERVICE...3280
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...3280
REPLACE HYDRAULIC TANK BREATHER ELEMENT...3281
CHECK AXLE OIL...3282
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...3282
CLEAN BRAKE CIRCUIT STRAINER...3283
CHECK BRAKE DISC WEAR...3284
CHECKING FUNCTION OF ACCUMULATOR...3285
CHECK ALTERNATOR, STARTING MOTOR...3285
CHECK ENGINE VALVE CLEARANCE, ADJUST...3285
CLEAN AND CHECK TURBOCHARGER...3285
CHECK VIBRATION DAMPER...3285
EVERY 4000 HOURS SERVICE...3286
LUBRICATING...3286
CHECK WATER PUMP...3286
SPECIFICATIONS...3287
SPECIFICATIONS...3288
ATTACHMENTS, OPTIONS...3290
SELECTING BUCKET AND TIRES...3291
HANDLING FORK TOOL...3292
EXPLANATION OF COMPONENTS...3292
OPERATION...3293
INDEX...3296
Komatsu Wheel Loaders WA200L, WA200PT(L) Repair Service Manual
