Komatsu Wheel Loader WA200, WA200PZ Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA200, WA200PZ, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA200, WA200PZ 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.
SEN03862-05 - Wheel Loader WA200-6, WA200PZ-6 Shop Manual.pdf
TEN00211-01 - Wheel Loader WA200-5 Operation & Maintenance Manual.pdf
TEN00212-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual.pdf
TEN00264-05 - Wheel Loader WA200PZ-6 Operation & Maintenance Manual.pdf
TEN00407-02 - Wheel Loader WA200PZ-6 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,311 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
SEN03862-05 - Wheel Loader WA200-6, WA200PZ-6 Shop Manual.....2
COVER.....2
00 INDEX AND FOREWORD.....0
100 Index.....4
Composition of shop manual.....5
Table of contents.....7
200 FOREWORD AND GENERAL INFORMATION.....18
SAFETY NOTICE.....19
HOW TO READ THE SHOP MANUAL.....24
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.....26
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT.....28
HANDLING OF CONNECTORS NEWLY USED FOR ENGINES.....37
HOW TO READ ELECTRIC WIRE CODE.....40
PRECAUTIONS WHEN CARRYING OUT OPERATION.....43
METHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLER.....46
STANDARD TIGHTENING TORQUE TABLE.....49
CONVERSION TABLE.....53
01 SPECIFICATION.....0
100 SPECIFICATION AND TECHNICAL DATA.....60
SPECIFICATION DIMENSION DRAWING.....62
SPECIFICATIONS.....63
WEIGHT TABLE.....67
TABLE OF FUEL, COOLANT AND LUBRICANTS.....69
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.....0
100 ENGINE AND COOLING SYSTEM.....72
ENGINE MOUNT AND TRANSFER MOUNT.....73
DAMPER.....74
COOLING SYSTEM.....75
COOLING SYSTEM HYDRAULIC PIPING DIAGRAM.....76
COOLING FAN MOTOR.....78
200 POWER TRAIN.....88
POWER TRAIN.....90
POWER TRAIN SYSTEM DIAGRAM.....91
DRIVE SHAFT.....93
HST HYDRAULIC PIPING DIAGRAM.....94
HST PUMP.....95
HST MOTOR.....103
TRANSFER.....109
CLUTCH SOLENOID VALVE.....120
AXLE.....121
DIFFERENTIAL.....123
TORQUE PROPORTIONING.....128
LIMITED SLIP DIFFERENTIAL.....131
FINAL DRIVE.....135
300 STEERING SYSTEM.....140
STEERING PIPING DIAGRAM.....142
STEERING COLUMN.....143
PRIORITY VALVE.....144
ORBIT-ROLL VALVE.....147
2-WAY RESTRICTOR VALVE.....155
CUSHION VALVE.....156
STEERING CYLINDER.....157
EMERGENCY STEERING PIPING DIAGRAM.....159
EMERGENCY STEERING VALVE.....160
STEERING RELIEF VALVE.....163
400 BRAKE SYSTEM.....166
BRAKE PIPING DIAGRA.....168
CHARGE VALVE.....169
BRAKE VALVE.....173
INCHING VALVE.....177
ACCUMULATOR (FOR BRAKE).....178
SLACK ADJUSTER.....179
BRAKE.....181
PARKING BRAKE CONTROL.....186
PARKING BRAKE.....187
500 UNDERCARRIAGE AND FRAME.....190
AXLE MOUNT AND CENTER HINGE PIN.....191
TIRES.....196
600 HYDRAULIC SYSTEM.....198
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM.....199
WORK EQUIPMENT CONTROL LEVER LINKAGE.....203
HYDRAULIC TANK.....207
4-GEAR PUMP.....209
WORK EQUIPMENT CONTROL VALVE .....212
PPC VALVE.....236
LOCK VALVE.....251
ACCUMULATOR (FOR PPC CIRCUIT).....252
BYPASS VALVE.....253
QUICK COUPLER SOLENOID VALVE.....256
ECSS VALVE.....257
ACCUMULATOR (FOR ECSS).....259
700 WORK EQUIPMENT.....262
WORK EQUIPMENT LINKAGE.....263
BUCKET.....267
BUCKET POSITIONER AND BOOM KICK-OUT.....271
WORK EQUIPMENT CYLINDER.....284
800 CAB AND ITS ATTACHMENTS.....288
CAB.....290
AIR CONDITIONER.....291
910 ELECTRICAL SYSTEM, PART 1.....304
MACHINE MONITOR SYSTEM.....305
MACHINE MONITOR.....309
920 ELECTRICAL SYSTEM, PART 2.....332
ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM).....333
HST CONTROLLER.....349
ECSS SYSTEM.....351
KOMTRAX SYSTEM.....353
ENGINE STARTING CIRCUIT.....355
ENGINE STOPPING CIRCUIT.....357
PREHEATING CIRCUIT.....358
ENGINE OUTPUT DERATING FUNCTION.....359
AUTOMATIC WARM-UP FUNCTION.....359
PARKING BRAKE CIRCUIT.....360
COUPLER PLUNGER CONTROL SYSTEM.....363
MULTI-FUNCTION KNOB.....364
MAX. TRACTION SWITCH.....365
SENSOR.....366
20 STANDARD VALUE TABLE.....0
100 STANDARD SERVICE VALUE TABLE.....374
STANDARD SERVICE VALUE TABLE FOR ENGINE.....375
STANDARD SERVICE VALUE TABLE FOR CHASSIS.....376
30 TESTING AND ADJUSTING.....0
110 TESTING AND ADJUSTING, PART 1.....384
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....385
Sketches of special tools.....390
Measuring engine speed.....391
Measuring exhaust gas color.....393
ADJUSTING VALVE CLEARANCE.....394
MEASURING COMPRESSION PRESSURE.....396
MEASURING BLOW-BY PRESSURE.....399
TESTING ENGINE OIL PRESSURE.....400
MEASURING INTAKE AIR (BOOST) PRESSURE.....401
HANDLING FUEL SYSTEM EQUIPMENT.....403
RELEASING RESIDUAL PRESSURE IN FUEL SYSTEM.....403
MEASURING FUEL PRESSURE.....404
MEASURING FUEL RETURN RATE AND LEAKAGE.....406
BLEEDING AIR FROM FUEL CIRCUIT.....410
Checking leakage in fuel system.....411
Handling cylinder cut-out mode operation.....412
Handling no-injection cranking operation.....412
HANDLING CONTROLLER VOLTAGE CIRCUIT.....413
CHECK OF MUFFLER AND MUFFLER STACK FOR LOOSENESS AND DAMAGE.....413
CHECK OF MUFFLER FUNCTION.....414
CHECK OF INSTALLED CONDITION OF CYLINDER HEAD AND MANIFOLDS.....414
CHECK OF ENGINE PIPING FOR DAMAGE AND LOOSENESS.....415
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.....415
REPLACING ALTERNATOR BELT.....416
120 TESTING AND ADJUSTING, PART 2.....418
CHECKING OPERATING FORCE OF ACCELERATOR PEDAL.....420
CHECKING DIRECTIONAL LEVER.....421
TESTING AND ADJUSTING HST OIL PRESSURE.....422
TESTING CLUTCH CONTROL PRESSURE.....427
TESTING AND ADJUSTING STEERING WHEEL.....428
TESTING AND ADJUSTING STEERING OIL PRESSURE.....430
BLEEDING AIR FROM STEERING CIRCUIT.....432
TESTING HYDRAULIC FAN.....433
MEASURING BRAKE PEDAL.....435
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.....436
MEASURING BRAKE PERFORMANCE.....437
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE.....438
TESTING WHEEL BRAKE OIL PRESSURE.....440
TESTING WEAR OF BRAKE DISC.....443
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT.....444
RELEASING RESIDUAL PRESSURE IN BRAKE ACCUMULATOR CIRCUIT.....445
TESTING PARKING BRAKE PERFORMANCE.....446
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE.....447
MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.....448
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.....449
TESTING WORK EQUIPMENT PPC OIL PRESSURE.....450
BLEEDING AIR FROM HYDRAULIC CIRCUIT.....452
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....453
TESTING AND ADJUSTING BUCKET POSITIONER.....454
TESTING AND ADJUSTING OF BOOM KICK-OUT SWITCH.....456
CHECKING PROXIMITY SWITCH OPERATION PILOT LAMP.....457
PROCEDURE FOR TESTING DIODES.....458
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM.....460
STARTING KOMTRAX TERMINAL OPERATIONS.....464
INDICATOR LAMPS OF KOMTRAX TERMINAL.....468
130 TESTING AND ADJUSTING, PART 3.....472
ADJUSTING MACHINE MONITOR.....473
ADJUSTING REPLACED, REASSEMBLED OR ADDED SENSOR, CONTROLLER, ETC. WITH MACHINE MONITOR.....474
SPECIAL FUNCTIONS OF MACHINE MONITOR (EMMS).....476
PM CLINIC INSPECTION CHART.....530
40 TROUBLESHOOTING.....0
100 FAILURE CODE TABLE AND FUSE LOCATIONS.....534
FAILURE CODES TABLE.....535
FUSE LOCATIONS.....541
200 General information on troubleshooting.....546
Points to remember when troubleshooting.....547
Sequence of events in troubleshooting.....548
Testing before troubleshooting.....549
Classification and procedures of troubleshooting.....550
Information contained in troubleshooting table.....553
Connection table for connector pin numbers.....555
T- branch box and T- branch adapter table.....591
310 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1.....596
FAILURE CODE [2G40GZ] BRAKE: OIL PRESSURE REDUCTION.....597
FAILURE CODE [6091NX] HST FILTER: CLOGGING.....599
FAILURE CODE [989FN1] TRAVEL SPEED: OVERRUN ALARM.....600
FAILURE CODE [AB00L6] ALTERNATOR R SYSTEM: HOT SHORT.....601
FAILURE CODE [AB00MA] ALTERNATOR R SYSTEM: GROUND FAULT/DISCONNECTION CHARGE/LOW CHARGE VOLTAGE.....603
FAILURE CODE [B@BAZG] ENGINE: OIL PRESSURE REDUCTION.....605
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT.....606
FAILURE CODE [B@BCZK] ENGINE: LOW COOLANT LEVEL.....607
FAILURE CODE [B@C6NS] FRONT BRAKE: HIGH OIL TEMPERATURE.....609
FAILURE CODE [B@CRNS] HST: HIGH OIL TEMPERATURE.....610
320 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2.....612
FAILURE CODE [CA111] ABNORMALITY IN ENGINE CONTROLLER.....614
FAILURE CODE [CA115] ENGINE NE OR BKUP SPEED SENSOR ERROR.....615
FAILURE CODE [CA122] CHARGE PRESSURE SENSOR HIGH ERROR.....617
FAILURE CODE [CA123] CHARGE PRESSURE SENSOR LOW ERROR.....619
FAILURE CODE [CA131] THROTTLE SENSOR HIGH ERROR.....621
FAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR.....623
FAILURE CODE [CA144] COOLANT SENSOR HIGH ERROR.....625
FAILURE CODE [CA145] COOLANT SENSOR LOW ERROR.....627
FAILURE CODE [CA153] CHARGE TEMPERATURE SENSOR HIGH ERROR.....629
FAILURE CODE [CA154] CHARGE TEMPERATURE SENSOR LOW ERROR.....631
FAILURE CODE [CA155] DERATING OF SPEED BY ABNORMALLY HIGH CHARGE TEMPERATURE.....633
FAILURE CODE [CA187] SENSOR POWER SUPPLY 2 LOW ERROR.....635
FAILURE CODE [CA221] ATMOSPHERIC PRESSURE SENSOR HIGH ERROR.....637
FAILURE CODE [CA222] ATMOSPHERIC SENSOR LOW ERROR.....639
FAILURE CODE [CA227] SENSOR POWER SUPPLY 2 HIGH ERROR.....641
FAILURE CODE [CA234] ENGINE OVERSPEED.....642
FAILURE CODE [CA238] NE SPEED SENSOR POWER SUPPLY ERROR.....643
FAILURE CODE [CA271] IMV (IMA) SHORT CIRCUIT.....644
FAILURE CODE [CA272] IMV (IMA) DISCONNECTION.....645
FAILURE CODE [CA322] INJECTOR #1 OPEN/SHORT ERROR.....647
FAILURE CODE [CA324] INJECTOR #3 OPEN/SHORT ERROR.....649
FAILURE CODE [CA331] INJECTOR #2 OPEN/SHORT ERROR.....651
FAILURE CODE [CA332] INJECTOR #4 OPEN/SHORT ERROR.....653
FAILURE CODE [CA342] CALIBRATION CODE INCONSISTENCY.....655
FAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERROR.....657
FAILURE CODE [CA352] SENSOR POWER SUPPLY 1 LOW ERROR.....659
FAILURE CODE [CA386] SENSOR POWER SUPPLY 1 HIGH ERROR.....661
330 Troubleshooting by failure code (Display of code), Part 3.....664
Failure code [CA428] Abnormally high level in water sensor.....667
Failure code [CA429] Abnormally low level in water sensor.....669
Failure code [CA431] Idle validation switch error.....671
Failure code [CA432] Idle validation action error.....675
Failure code [CA435] Engine oil pressure switch error.....679
Failure code [CA441] Battery voltage low error.....680
Failure code [CA442] Battery voltage high error.....683
Failure code [CA449] Common rail pressure high error 2.....685
Failure code [CA451] Common rail pressure sensor high error.....687
Failure code [CA452] Common rail pressure sensor low error.....689
Failure code [CA488] Derating of torque by abnormally high charge temperature.....691
Failure code [CA553] Common rail pressure high error 1.....692
Failure code [CA559] Supply pump pressure very low error.....693
Failure code [CA689] Engine Ne speed sensor error.....695
Failure code [CA731] Engine Bkup speed sensor phase error.....697
Failure code [CA757] All continuous data lost error.....698
Failure code [CA778] Engine Bkup speed sensor error.....701
Failure code [CA1633] KOMNET datalink timeout error.....703
Failure code [CA2185] Throttle sensor supply voltage high error.....705
Failure code [CA2186] Throttle sensor power supply low error.....707
Failure code [CA2249] Supply pump pressure very low error 2.....709
Failure code [CA2311] Abnormality in IMV (IMA) solenoid.....711
Failure code [CA2555] Intake heater relay disconnection error.....713
Failure code [CA2556] Intake heater relay short circuit error.....715
340 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 4.....718
FAILURE CODE [D160KY] BACKUP ALARM/LAMP RELAY 1 CIRCUIT: HOT SHORT.....719
FAILURE CODE [D192KY] ECSS SOLENOID RELAY: HOT SHORT.....721
FAILURE CODE [D1B0KA] HST SAFETY RELAY: DISCONNECTION.....723
FAILURE CODE [D1B0KB] HST SAFETY RELAY: GROUND FAULT.....725
FAILURE CODE [D1B0KY] HST SAFETY RELAY: HOT SHORT.....727
FAILURE CODE [D5ZHL6] IGN C SYSTEM: GROUND FAULT/DISCONNECTION.....729
FAILURE CODE [DAF3KK] UNSW POWER SUPPLY: GROUND FAULT/DISCONNECTION.....731
FAILURE CODE [DAFRKR] MACHINE MONITOR CAN-NET SIGNAL: DISCONNECTION.....733
FAILURE CODE [DAJ0KK] HST CONTROLLER POWER SUPPLY: LOW VOLTAGE.....737
FAILURE CODE [DAJ0KT] HST CONTROLLER MEMORY (EEPROM): ABNORMALITY.....739
FAILURE CODE [DAJ1L4] HST CONTROLLER MAIN POWER LINE: DISCONNECTION/GROUND FAULT.....741
FAILURE CODE [DAJ1L6] HST CONTROLLER MAIN POWER LINE: HOT SHORT.....743
FAILURE CODE [DAJ2KK] CONTROLLER SOLENOID POWER SUPPLY: LOW VOLTAGE.....745
FAILURE CODE [DAJ2L3] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: HOT SHORT IN WIRING HARNESS.....747
FAILURE CODE [DAJ2L4] HST CONTROLLER LOAD POWER SUPPLY HOLDING LINE: DISCONNECTION/GROUND FAULT.....749
FAILURE CODE [DAJ5KX] SENSOR 5V POWER SUPPLY: OUT OF OUTPUT RANGE.....751
FAILURE CODE [DAJ9KQ] HST CONTROLLER MODEL SELECTION: DISAGREEMENT OF MODEL SELECTION SIGNALS.....753
FAILURE CODE [DAJRKR] HST CONTROLLER CAN-NET SIGNAL: DISCONNECTION.....754
FAILURE CODE [DAJRMA] HST CONTROLLER: DISAGREEMENT IN OPTION SELECTION.....760
350 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 5.....762
FAILURE CODE [DB2RKR] ENGINE CONTROLLER CAN-NET: DISCONNECTION IN SIGNAL LINE.....763
FAILURE CODE [DD1NL4] FAN AUTOMATIC REVERSE SWITCH SIGNAL: ABNORMALITY.....769
FAILURE CODE [DD1NLD] FAN REVERSE SWITCH SIGNAL: ABNORMALITY.....771
FAILURE CODE [DDB6KA] PARKING BRAKE SWITCH A: DISCONNECTION/HOT SHORT.....773
FAILURE CODE [DDB6KB] PARKING BRAKE SWITCH B: GROUND FAULT.....775
FAILURE CODE [DDB6KZ] PARKING BRAKE SWITCH (BOTTOM SWITCH) OR PARKING BRAKE REMINDER SWITCH (INTERMEDIATE SWITCH): TROUBLE.....777
FAILURE CODE [DDB6L0] PARKING BRAKE SWITCH A: GROUND FAULT.....779
FAILURE CODE [DDB6L4] PARKING BRAKE SWITCH B: DISCONNECTION/HOT SHORT.....781
FAILURE CODE [DDD7KX] TRAVEL SPEED CONTROL DIAL SIGNAL: DISCONNECTION/GROUND FAULT.....783
FAILURE CODE [DDD7KY] TRAVEL SPEED CONTROL DIAL SIGNAL: HOT SHORT.....785
FAILURE CODE [DDE5MA] EMERGENCY STEERING OPERATION SWITCH: DISCONNECTION.....787
FAILURE CODE [DDK3KA] DIRECTIONAL SELECTOR SWITCH: DISCONNECTION/HOT SHORT.....789
FAILURE CODE [DDK3KB] DIRECTIONAL SELECTOR SWITCH: GROUND FAULT.....791
FAILURE CODE [DDK6KA] FNR LEVER: DISCONNECTION/GROUND FAULT.....793
FAILURE CODE [DDK6KY] FNR LEVER: HOT SHORT.....797
FAILURE CODE [DDS5L6] STEERING: LOW OIL PRESSURE (OPERATION OF EMERGENCY STEERING).....799
360 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 6.....802
FAILURE CODE [DF10KA] TRAVEL SPEED RANGE SELECTOR SWITCH: DISCONNECTION/GROUND FAULT.....803
FAILURE CODE [DF10KB] TRAVEL SPEED RANGE SELECTOR SWITCH: HOT SHORT.....807
FAILURE CODE [DGH1KX] HST OIL TEMPERATURE SENSOR: GROUND FAULT.....809
FAILURE CODE [DGR2KB] BRAKE OIL TEMPERATURE SENSOR: GROUND FAULT.....810
FAILURE CODE [DGR2KZ] BRAKE OIL TEMPERATURE SENSOR: DISCONNECTION/HOT SHORT.....811
FAILURE CODE [DHH1KX] HST OIL PRESSURE SENSOR: DISCONNECTION/GROUND FAULT.....813
FAILURE CODE [DHH1KY] HST OIL PRESSURE SENSOR: HOT SHORT.....815
FAILURE CODE [DHTCL6] HST FILTER CLOGGING SENSOR: FUNCTIONAL DEFECT.....817
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: DISCONNECTION/HOT SHORT.....819
FAILURE CODE [DLT3KX] TRAVEL SPEED SENSOR B: ABNORMALITY.....821
FAILURE CODE [DLT4KX] TRAVEL SPEED SENSOR A: ABNORMALITY.....825
FAILURE CODE [DLT4LC] TRAVEL SPEED SENSOR A & B: ABNORMALITY.....827
FAILURE CODE [DV00KY] ALARM BUZZER: HOT SHORT.....829
FAILURE CODE [DW26KA] MOTOR 2 SOLENOID: DISCONNECTION/GROUND FAULT.....831
FAILURE CODE [DW26KY] MOTOR 2 SOLENOID: HOT SHORT.....833
FAILURE CODE [DW7BKY] FAN REVERSE SOLENOID CIRCUIT: HOT SHORT.....835
FAILURE CODE [DW7BKZ] FAN REVERSE SOLENOID CIRCUIT: DISCONNECTION/GROUND FAULT.....837
370 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 7.....840
FAILURE CODE [DX16KA] FAN EPC SOLENOID: DISCONNECTION.....841
FAILURE CODE [DX16KB] FAN EPC SOLENOID: GROUND FAULT.....842
FAILURE CODE [DX16KY] FAN EPC SOLENOID: HOT SHORT.....843
FAILURE CODE [DX19KA] MOTOR 1 SOLENOID: DISCONNECTION.....845
FAILURE CODE [DX19KB] MOTOR 1 SOLENOID: GROUND FAULT.....847
FAILURE CODE [DX19KY] MOTOR 1 SOLENOID: HOT SHORT.....849
FAILURE CODE [DX20KA] CLUTCH EPC SOLENOID: DISCONNECTION.....851
FAILURE CODE [DX20KB] CLUTCH EPC SOLENOID: GROUND FAULT.....853
FAILURE CODE [DX20KY] CLUTCH EPC SOLENOID: HOT SHORT.....855
FAILURE CODE [DXH7KB] REVERSE SOLENOID: GROUND FAULT.....857
FAILURE CODE [DXH7KZ] REVERSE SOLENOID: DISCONNECTION/HOT SHORT.....859
FAILURE CODE [DXH8KB] FORWARD SOLENOID: GROUND FAULT.....861
FAILURE CODE [DXH8KZ] FORWARD SOLENOID: DISCONNECTION/HOT SHORT.....863
FAILURE CODE [J141N1] STEERING PUMP: OVERRUN ALARM.....865
FAILURE CODE [M100N1] HST PUMP: OVERRUN ALARM.....865
FAILURE CODE [M400N1] MOTOR 1: OVERRUN ALARM.....866
400 Troubleshooting of electrical system(E-mode).....868
E-1 Engine does not start.....870
E-2. Preheater does not operate normally.....877
E-3 Travel speed is low or high.....881
E-4 ECSS does not operate.....887
E-5 ECSS keeps operating.....890
E-6 Defective boom kick-out function and cancellation.....893
E-7 Defective bucket positioner function and cancellation.....897
E-8 Defective lift arm FLOATING holding function and cancellation.....901
E-9 Travel direction selection system does not function.....905
E-10 Fan does not reverse.....909
E-11 Fan keeps rotating in reverse.....913
E-12 Wiper does not operate.....915
E-13 Windshield washer does not operate.....919
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off.....923
E-15 Working lamp does not light up or go off.....931
E-16 Turn signal lamp and hazard lamp do not light up or go off.....936
E-17 Brake lamp does not light or it keeps lighting up.....943
E-18 Backup lamp does not light or it keeps lighting up.....945
E-19 Backup alarm does not sound or it keeps sounding.....948
E-20 Horn does not sound or it keeps sounding.....951
E-21 Alarm buzzer does not sound or it keeps sounding.....953
E-22 Air conditioner does not operate or stop.....956
E-23 The KOMTRAX system does not work properly.....959
500 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).....962
METHOD OF USING TROUBLESHOOTING CHART.....964
FAILURE CODE AND CAUSE TABLE.....967
H-1 THE MACHINE DOES NOT START.....969
H-2 THE TRAVEL SPEED IS SLOW.....970
H-3 THE TRACTION FORCE IS WEAK.....971
H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY.....972
H-5 THE GEAR IS NOT SHIFTED.....973
H-6 THE STEERING WHEEL DOES NOT TURN.....974
H-7 THE STEERING WHEEL IS HEAVY.....975
H-8 STEERING WHEEL SHAKES OR JERKS.....976
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING.....976
H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL.....977
H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED.....978
H-12 THE LIFT ARM DOES NOT RISE OR LOWER.....979
H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.....980
H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT.....981
H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR).....981
H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN.....981
H-17 THE LIFT ARM WOBBLES DURING OPERATION.....981
H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ RAISE, ” THE LIFT ARM FALLS TEMPORARILY.....982
H-19 THE BUCKET DOES NOT TILT BACK.....983
H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT.....984
H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK.....985
H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.....985
H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.....985
H-24 THE BUCKET WOBBLES DURING TRAVEL WITH LOAD (THE WORK EQUIPMENT VALVE IS SET TO “ HOLD ” ).....985
H-25 WHEN THE CONTROL LEVER IS SWITCHED FROM “ HOLD ” TO “ TILT, ” THE BUCKET FALLS TEMPORARILY.....986
H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY.....986
H-27 THE ECSS DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.....987
H-28 FAN REVOLUTION IS ABNORMAL (FAN SOUND/VIBRATION IS ABNORMALLY LARGE OR ENGINE OVERHEATS).....988
600 TROUBLESHOOTING OF ENGINE (S-MODE).....990
METHOD OF USING TROUBLESHOOTING CHARTS.....991
S-1 STARTING PERFORMANCE IS POOR.....995
S-2 ENGINE DOES NOT START.....996
S-3 ENGINE DOES NOT PICK UP SMOOTHLY.....999
S-4 ENGINE STOPS DURING OPERATIONS.....1000
S-5 ENGINE DOES NOT ROTATE SMOOTHLY.....1001
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).....1002
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).....1003
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).....1004
S-9 OIL BECOMES CONTAMINATED QUICKLY.....1005
S-10 FUEL CONSUMPTION IS EXCESSIVE.....1006
S-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN).....1007
S-12 OIL PRESSURE DROPS.....1008
S-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL).....1009
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....1010
S-15 ABNORMAL NOISE IS MADE.....1011
S-16 VIBRATION IS EXCESSIVE.....1012
50 DISASSEMBLY AND ASSEMBLY.....0
100 GENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLY.....1014
HOW TO READ THIS MANUAL.....1015
COATING MATERIALS LIST.....1017
SPECIAL TOOL LIST.....1020
SKETCHES OF SPECIAL TOOLS.....1024
200 ENGINE AND COOLING SYSTEM.....1034
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY.....1035
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.....1038
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.....1045
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY.....1058
REMOVAL AND INSTALLATION OF RADIATOR.....1062
REMOVAL AND INSTALLATION OF AIR AFTERCOOLER.....1065
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY.....1067
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY.....1069
REMOVAL AND INSTALLATION OF ENGINE FRONT OIL SEAL ASSEMBLY.....1076
REMOVAL AND INSTALLATION OF ENGINE REAR OIL SEAL ASSEMBLY.....1079
REMOVAL AND INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY.....1082
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.....1085
310 POWER TRAIN, PART 1.....1088
DISASSEMBLY AND ASSEMBLY OF TRANSFER ASSEMBLY.....1089
REMOVAL AND INSTALLATION OF PARKING BRAKE ASSEMBLY.....1108
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY.....1110
320 POWER TRAIN, PART 2.....1116
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY.....1117
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY.....1119
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY.....1122
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY.....1130
400 UNDERCARRIAGE AND FRAME.....1158
REMOVAL AND INSTALLATION OF CENTER HINGE PIN.....1159
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.....1168
500 HYDRAULIC SYSTEM.....1172
REMOVAL AND INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY.....1173
DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY.....1177
REMOVAL AND INSTALLATION OF HST MOTOR 1 ASSEMBLY.....1204
REMOVAL AND INSTALLATION OF HST MOTOR 2 ASSEMBLY.....1206
DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY.....1208
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.....1224
REMOVAL AND INSTALLATION OF HYDRAULIC TANK.....1226
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.....1228
600 WORK EQUIPMENT.....1234
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....1235
700 CAB AND ITS ATTACHMENTS.....1244
REMOVAL AND INSTALLATION OF OPERATOR'S CAB AND FLOOR FRAME ASSEMBLY.....1245
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).....1250
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT.....1258
800 ELECTRICAL SYSTEM.....1266
REMOVAL AND INSTALLATION OF MONITOR PANEL.....1267
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY.....1269
REMOVAL AND INSTALLATION OF HST CONTROLLER ASSEMBLY.....1271
REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL ASSEMBLY.....1272
90 DIAGRAMS AND DRAWINGS.....0
100 HYDRAULIC DIAGRAMS AND DRAWINGS.....1274
HYDRAULIC CIRCUIT DIAGRAM.....1276
200 ELECTRICAL DIAGRAMS AND DRAWINGS.....1280
ELECTRICAL CIRCUIT DIAGRAM.....1282
CONNECTOR LIST AND STEREOGRAM.....1292
TEN00211-01 - Wheel Loader WA200-5 Operation & Maintenance Manual.....1295
COVER.....1295
FOREWORD.....1296
FOREWORD.....1297
SAFETY INFORMATION.....1300
INTRODUCTION.....1302
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....1302
NECESSARY INFORMATION.....1303
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....1303
ENGINE SERIAL NO. PLATE.....1303
POSITION OF SERVICE METER.....1304
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....1304
CONTENTS.....1305
SAFETY.....1308
SAFETY.....1309
SAFETY LABELS.....1312
LOCATION OF SAFETY LABELS.....1312
SAFETY LABELS.....1313
GENERAL PRECAUTIONS.....1318
PRECAUTIONS FOR OPERATION.....1327
STARTING ENGINE.....1327
OPERATION.....1329
TRANSPORTATION.....1335
BATTERY.....1336
TOWING.....1338
PRECAUTIONS FOR MAINTENANCE.....1339
PRECAUTIONS WITH TIRES.....1346
OPERATION.....1348
GENERAL VIEW.....1349
GENERAL VIEW OF MACHINE.....1349
GENERAL VIEW OF CONTROLS AND GAUGES.....1350
EXPLANATION OF COMPONENTS.....1352
MACHINE MONITOR.....1352
SWITCHES.....1378
CONTROL LEVERS, PEDALS.....1385
STEERING TILT LOCK LEVER.....1389
CAP AND COVER WITH LOCK.....1389
FRAME LOCK BAR.....1390
TOWING PIN.....1391
GREASE PUMP.....1391
CAB DOOR INNER LOCK.....1391
CAB DOOR OPEN LOCK.....1392
CAB WINDOW OPEN LOCK CANCEL KNOB.....1392
FUSE.....1392
SLOW BLOW FUSE.....1394
POWER OUTLET.....1394
STORAGE BOX.....1394
AM/FM RADIO.....1395
AM/FM RADIO-CASSETTE STEREO.....1401
AIR CONDITIONER.....1409
HANDLING CAB WIPER.....1414
HANDLING MACHINES EQUIPPED WITH KOMTRAX.....1415
OPERATION.....1416
CHECK BEFORE STARTING ENGINE, ADJUST.....1416
STARTING ENGINE.....1432
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....1434
STOPPING ENGINE.....1436
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.....1437
TURNING.....1441
OPERATION OF WORK EQUIPMENT.....1443
WORK POSSIBLE USING WHEEL LOADER.....1445
PRECAUTIONS FOR OPERATION.....1450
ADJUSTING WORK EQUIPMENT POSTURE.....1452
PARKING MACHINE.....1454
CHECKS AFTER COMPLETION OF OPERATION.....1456
LOCKING.....1456
HANDLING THE TIRES.....1457
TRANSPORTATION.....1459
TRANSPORTATION PROCEDURE.....1459
LOADING, UNLOADING WORK WITH TRAILERS.....1459
LIFTING MACHINE.....1463
COLD WEATHER OPERATION.....1465
PRECAUTIONS FOR LOW TEMPERATURE.....1465
PRECAUTIONS AFTER COMPLETION OF WORK.....1466
AFTER COLD WEATHER.....1466
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.....1467
LONG-TERM STORAGE.....1468
BEFORE STORAGE.....1468
DURING STORAGE.....1468
AFTER STORAGE.....1468
TROUBLESHOOTING.....1469
WHEN MACHINE RUNS OUT OF FUEL.....1469
METHOD OF TOWING MACHINE.....1469
IF BATTERY IS DISCHARGED.....1471
OTHER TROUBLE.....1474
MAINTENANCE.....1480
GUIDES TO MAINTENANCE.....1481
OUTLINES OF SERVICE.....1483
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....1483
OUTLINE OF ELECTRIC SYSTEM.....1486
WEAR PARTS.....1487
WEAR PARTS LIST.....1487
RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....1488
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....1489
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.....1490
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....1491
TORQUE LIST.....1491
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....1492
MAINTENANCE SCHEDULE CHART.....1493
MAINTENANCE SCHEDULE CHART.....1493
SERVICE PROCEDURE.....1495
INITIAL 250 HOURS SERVICE.....1495
WHEN REQUIRED.....1496
CHECK BEFORE STARTING.....1516
EVERY 50 HOURS SERVICE.....1517
EVERY 100 HOURS SERVICE.....1518
EVERY 250 HOURS SERVICE.....1520
EVERY 500 HOURS SERVICE.....1526
EVERY 1000 HOURS SERVICE.....1530
EVERY 2000 HOURS SERVICE.....1535
EVERY 4000 HOURS SERVICE.....1542
SPECIFICATIONS.....1544
SPECIFICATIONS.....1545
ATTACHMENTS, OPTIONS.....1548
SELECTING BUCKET AND TIRES.....1549
HANDLING BATTERY DISCONNECTOR SWITCH.....1550
EXPLANATION OF COMPONENTS.....1550
HANDLING.....1550
INDEX.....1552
TEN00212-00 - Wheel Loader GALEO WA200L-5 Operation & Maintenance Manual.....1556
COVER.....1556
FOREWORD.....1557
FOREWORD.....1558
SAFETY INFORMATION.....1561
INTRODUCTION.....1563
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....1563
NECESSARY INFORMATION.....1564
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....1564
ENGINE SERIAL NO. PLATE.....1564
POSITION OF SERVICE METER.....1565
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....1565
CONTENTS.....1566
SAFETY.....1569
SAFETY.....1570
SAFETY LABELS.....1573
LOCATION OF SAFETY LABELS.....1573
SAFETY LABELS.....1574
GENERAL PRECAUTIONS.....1579
SAFETY RULES.....1579
IF ABNORMALITIES ARE FOUND.....1579
CLOTHING AND PERSONAL PROTECTIVE ITEMS.....1579
FIRE EXTINGUISHER AND FIRST AID KIT.....1579
SAFETY FEATURES.....1579
KEEP MACHINE CLEAN.....1580
INSIDE OPERATOR'S COMPARTMENT.....1580
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.....1580
HANDRAILS AND STEPS.....1581
MOUNTING AND DISMOUNTING.....1582
NO PEOPLE ON ATTACHMENTS.....1582
DO NOT GET CAUGHT IN ARTICULATED PORTION.....1582
PREVENTION OF BURNS.....1582
FIRE PREVENTION.....1583
ACTION IF FIRE OCCURS.....1584
WINDOW WASHER LIQUID.....1584
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE).....1584
PRECAUTIONS FOR ATTACHMENTS, OPTIONS.....1584
UNAUTHORIZED MODIFICATION.....1584
SAFETY AT WORKSITE.....1585
WORKING ON LOOSE GROUND.....1585
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.....1585
ENSURE GOOD VISIBILITY.....1586
VENTILATION FOR ENCLOSED AREAS.....1586
CHECKING SIGNALMAN'S SIGNALS AND SIGNS.....1586
EMERGENCY EXIT FROM OPERATOR'S CAB.....1586
BE CAREFUL ABOUT ASBESTOS DUST.....1587
PRECAUTIONS FOR OPERATION.....1588
STARTING ENGINE.....1588
CHECKS BEFORE STARTING ENGINE.....1588
PRECAUTIONS WHEN STARTING.....1588
PRECAUTIONS IN COLD AREAS.....1589
OPERATION.....1590
CHECKS BEFORE OPERATION.....1590
PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE.....1590
PRECAUTIONS WHEN TRAVELING.....1591
TRAVELING ON SLOPES.....1592
PROHIBITED OPERATIONS.....1593
PRECAUTIONS WHEN OPERATING.....1593
METHODS OF USING BRAKE.....1594
OPERATE CAREFULLY ON SNOW.....1594
PARKING MACHINE.....1595
TRANSPORTATION.....1596
LOADING AND UNLOADING.....1596
SHIPPING.....1596
BATTERY.....1597
BATTERY HAZARD PREVENTION.....1597
STARTING WITH BOOSTER CABLES.....1598
TOWING.....1599
WHEN TOWING.....1599
PRECAUTIONS FOR MAINTENANCE.....1600
WARNING TAG.....1600
KEEP WORK PLACE CLEAN AND TIDY.....1600
APPOINT LEADER WHEN WORKING WITH OTHERS.....1600
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE.....1601
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.....1602
INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF.....1602
PROPER TOOLS.....1603
ACCUMULATOR.....1603
PERSONNEL.....1603
ATTACHMENTS.....1603
WORK UNDER THE MACHINE.....1604
NOISE.....1604
PRECAUTIONS WHEN USING HAMMER.....1604
REPAIR WELDING.....1604
REMOVING BATTERY TERMINAL.....1604
PRECAUTIONS WITH HIGH-PRESSURE OIL.....1605
HANDLING HIGH-PRESSURE HOSES.....1605
WASTE MATERIALS.....1605
MAINTENANCE OF AIR CONDITIONER.....1605
COMPRESSED AIR.....1606
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....1606
PRECAUTIONS WITH TIRES.....1607
HANDLING TIRES.....1607
PRECAUTIONS WHEN STORING TIRES.....1607
OPERATION.....1609
GENERAL VIEW.....1610
GENERAL VIEW OF MACHINE.....1610
GENERAL VIEW OF CONTROLS AND GAUGES.....1611
EXPLANATION OF COMPONENTS.....1613
MACHINE MONITOR.....1613
SWITCHES.....1639
CONTROL LEVERS, PEDALS.....1648
STEERING TILT LOCK LEVER.....1652
CAP AND COVER WITH LOCK.....1652
FRAME LOCK BAR.....1653
TOWING PIN.....1654
GREASE PUMP.....1654
CAB DOOR INNER LOCK.....1654
CAB DOOR OPEN LOCK.....1655
CAB WINDOW OPEN LOCK CANCEL KNOB.....1655
FUSE.....1655
SLOW BLOW FUSE.....1657
POWER OUTLET.....1657
STORAGE BOX.....1657
AM/FM RADIO-CASSETTE STEREO.....1658
AIR CONDITIONER.....1666
HANDLING CAB WIPER.....1671
HANDLING MACHINES EQUIPPED WITH KOMTRAX.....1672
OPERATION.....1673
CHECK BEFORE STARTING ENGINE, ADJUST.....1673
STARTING ENGINE.....1688
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....1690
STOPPING ENGINE.....1692
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.....1693
TURNING.....1698
OPERATION OF WORK EQUIPMENT.....1700
WORK POSSIBLE USING WHEEL LOADER.....1702
PRECAUTIONS FOR OPERATION.....1707
ADJUSTING WORK EQUIPMENT POSTURE.....1709
PARKING MACHINE.....1711
CHECKS AFTER COMPLETION OF OPERATION.....1713
LOCKING.....1713
HANDLING THE TIRES.....1714
TRANSPORTATION.....1716
TRANSPORTATION PROCEDURE.....1716
LOADING, UNLOADING WORK WITH TRAILERS.....1716
LIFTING MACHINE.....1720
COLD WEATHER OPERATION.....1722
PRECAUTIONS FOR LOW TEMPERATURE.....1722
PRECAUTIONS AFTER COMPLETION OF WORK.....1723
AFTER COLD WEATHER.....1723
WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER.....1724
LONG-TERM STORAGE.....1725
BEFORE STORAGE.....1725
DURING STORAGE.....1725
AFTER STORAGE.....1725
TROUBLESHOOTING.....1726
WHEN MACHINE RUNS OUT OF FUEL.....1726
METHOD OF TOWING MACHINE.....1726
IF BATTERY IS DISCHARGED.....1728
OTHER TROUBLE.....1731
MAINTENANCE.....1737
GUIDES TO MAINTENANCE.....1738
OUTLINES OF SERVICE.....1740
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....1740
OUTLINE OF ELECTRIC SYSTEM.....1743
WEAR PARTS.....1744
WEAR PARTS LIST.....1744
RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....1745
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....1746
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.....1747
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....1748
TORQUE LIST.....1748
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....1749
MAINTENANCE SCHEDULE CHART.....1750
MAINTENANCE SCHEDULE CHART.....1750
SERVICE PROCEDURE.....1752
INITIAL 250 HOURS SERVICE.....1752
WHEN REQUIRED.....1753
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT.....1753
CLEAN INSIDE OF COOLING SYSTEM.....1756
CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL.....1759
CHECK AXLE OIL LEVEL, ADD OIL.....1761
CLEAN AXLE CASE BREATHER.....1762
CLEAN AIR CONDITIONER CONDENSER.....1763
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID.....1763
CLEAN RADIATOR FINS AND COOLER FINS.....1764
CHECK ELECTRICAL INTAKE AIR HEATER.....1764
TURN, REPLACE BOLT-ON CUTTING EDGE.....1765
REPLACE BUCKET TEETH.....1766
CHECK AIR CONDITIONER.....1768
REPLACE SLOW BLOW FUSE.....1769
CHECKING FUNCTION OF ACCUMULATOR.....1770
SELECTION AND INSPECTION OF TIRES.....1771
CHECK BEFORE STARTING.....1773
EVERY 50 HOURS SERVICE.....1774
DRAIN WATER, SEDIMENT FROM FUEL TANK.....1774
EVERY 100 HOURS SERVICE.....1775
LUBRICATE REAR AXLE PIVOT PIN.....1775
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.....1775
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....1776
EVERY 250 HOURS SERVICE.....1777
CHECK BATTERY ELECTROLYTE LEVEL.....1777
CHECK PARKING BRAKE.....1779
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....1779
CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.....1780
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.....1781
CHECKING FUNCTION OF ACCUMULATOR.....1781
LUBRICATING.....1782
EVERY 500 HOURS SERVICE.....1783
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....1783
REPLACE FUEL FILTER CARTRIDGE.....1784
CLEAN WATER SEPARATOR STRAINER.....1785
EVERY 1000 HOURS SERVICE.....1786
CHANGE OIL IN TRANSFER CASE.....1786
CLEAN TRANSFER CASE BREATHER.....1787
REPLACE HST OIL FILTER ELEMENT.....1788
LUBRICATING.....1789
CHECK TIGHTENING PARTS OF TURBOCHARGER.....1789
CHECK PLAY OF TURBOCHARGER ROTOR.....1789
CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT.....1789
EVERY 2000 HOURS SERVICE.....1790
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....1790
REPLACE HYDRAULIC TANK BREATHER ELEMENT.....1791
CHANGE AXLE OIL.....1792
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.....1792
CLEAN BRAKE CIRCUIT STRAINER.....1793
CHECK BRAKE DISC WEAR.....1794
CHECKING FUNCTION OF ACCUMULATOR.....1795
CHECK ALTERNATOR, STARTING MOTOR.....1795
CHECK ENGINE VALVE CLEARANCE, ADJUST.....1795
CLEAN AND CHECK TURBOCHARGER.....1795
CHECK VIBRATION DAMPER.....1795
EVERY 4000 HOURS SERVICE.....1796
LUBRICATING.....1796
CHECK WATER PUMP.....1796
SPECIFICATIONS.....1797
SPECIFICATIONS.....1798
ATTACHMENTS, OPTIONS.....1801
SELECTING BUCKET AND TIRES.....1802
INDEX.....1803
TEN00264-05 - Wheel Loader WA200PZ-6 Operation & Maintenance Manual.....1807
COVER.....1807
FOREWORD.....1808
BEFORE READING THIS MANUAL.....1809
SAFETY INFORMATION.....1810
INTRODUCTION.....1811
USE OF MACHINE.....1811
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....1811
VISIBILITY FROM OPERATOR'S SEAT.....1811
NECESSARY INFORMATION.....1812
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....1812
EPA REGULATIONS, ENGINE NUMBER PLATE.....1812
POSITION OF SERVICE METER.....1813
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....1813
CONTENTS.....1814
SAFETY.....1818
SAFETY.....1819
SAFETY LABELS.....1822
LOCATION OF SAFETY LABELS.....1822
SAFETY LABELS.....1823
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.....1829
PRECAUTIONS BEFORE STARTING OPERATION.....1829
PREPARATIONS FOR SAFE OPERATION.....1829
FIRE PREVENTION.....1831
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.....1832
DO NOT GET CAUGHT IN ARTICULATING PORTION.....1835
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.....1835
UNAUTHORIZED MODIFICATION.....1835
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.....1835
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING.....1836
PRECAUTIONS FOR OPERATION.....1837
PRECAUTIONS FOR JOBSITE.....1837
STARTING ENGINE.....1839
OPERATION.....1841
TRANSPORTATION.....1848
TOWING.....1849
PRECAUTIONS FOR MAINTENANCE.....1850
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE.....1850
PRECAUTIONS FOR INSPECTION AND MAINTENANCE.....1855
TIRES.....1860
OPERATION.....1862
GENERAL VIEW.....1863
GENERAL VIEW OF MACHINE.....1863
GENERAL VIEW OF CONTROLS AND GAUGES.....1864
EXPLANATION OF COMPONENTS.....1866
MACHINE MONITOR.....1866
SWITCHES.....1903
CONTROL LEVERS, PEDALS.....1917
STEERING TILT LOCK LEVER.....1922
CAP AND COVER WITH LOCK.....1922
FRAME LOCK BAR.....1923
TOWING PIN.....1924
GREASE PUMP.....1924
OPENING, CLOSING CAB DOORS, WINDOWS.....1925
FUSE.....1929
SLOW BLOW FUSE.....1931
POWER OUTLET.....1932
STORAGE BOX.....1932
AM/FM RADIO-CASSETTE STEREO.....1933
AIR CONDITIONER.....1941
HANDLING CAB WIPER.....1948
OPERATION.....1949
CHECK BEFORE STARTING ENGINE, ADJUST.....1949
STARTING ENGINE.....1967
CHECKS AFTER STARTING ENGINE.....1971
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....1972
STOPPING ENGINE.....1975
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.....1976
TURNING.....1982
OPERATION OF WORK EQUIPMENT.....1984
HANDLING HYDRAULIC QUICK COUPLER.....1986
WORK POSSIBLE USING WHEEL LOADER.....1990
PRECAUTIONS FOR OPERATION.....1996
ADJUSTING WORK EQUIPMENT POSTURE.....1998
PARKING MACHINE.....2001
CHECKS AFTER COMPLETION OF OPERATION.....2003
LOCKING.....2003
HANDLING THE TIRES.....2004
TRANSPORTATION.....2006
TRANSPORTATION PROCEDURE.....2006
LOADING, UNLOADING WORK WITH TRAILERS.....2006
LIFTING MACHINE.....2010
COLD WEATHER OPERATION.....2012
PRECAUTIONS FOR LOW TEMPERATURE.....2012
PRECAUTIONS AFTER COMPLETION OF WORK.....2013
AFTER COLD WEATHER.....2013
LONG-TERM STORAGE.....2014
BEFORE STORAGE.....2014
DURING STORAGE.....2014
AFTER STORAGE.....2014
TROUBLESHOOTING.....2015
WHEN MACHINE RUNS OUT OF FUEL.....2015
METHOD OF TOWING MACHINE.....2015
IF BATTERY IS DISCHARGED.....2017
OTHER TROUBLE.....2020
MAINTENANCE.....2026
GUIDES TO MAINTENANCE.....2027
OUTLINES OF SERVICE.....2029
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....2029
OUTLINE OF ELECTRIC SYSTEM.....2032
WEAR PARTS.....2033
WEAR PARTS LIST.....2033
RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....2034
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....2035
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.....2036
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....2037
TORQUE LIST.....2037
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....2038
MAINTENANCE SCHEDULE CHART.....2039
MAINTENANCE SCHEDULE CHART.....2039
SERVICE PROCEDURE.....2041
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE).....2041
INITIAL 250 HOURS SERVICE.....2041
INITIAL 1000 HOURS SERVICE.....2041
WHEN REQUIRED.....2042
CHECK BEFORE STARTING.....2069
EVERY 50 HOURS SERVICE.....2070
EVERY 100 HOURS SERVICE.....2071
EVERY 250 HOURS SERVICE.....2074
EVERY 500 HOURS SERVICE.....2080
EVERY 1000 HOURS SERVICE.....2084
EVERY 2000 HOURS SERVICE.....2090
EVERY 4000 HOURS SERVICE.....2097
EVERY 8000 HOURS SERVICE.....2099
SPECIFICATIONS.....2100
SPECIFICATIONS.....2101
ATTACHMENTS, OPTIONS.....2104
SELECTING BUCKET AND TIRES.....2105
HANDLING FORK TOOL.....2106
EXPLANATION OF COMPONENTS.....2106
OPERATION.....2107
METHOD OF USING 3 LEVERS.....2110
EXPLANATION OF COMPONENTS.....2110
HANDLING MACHINES EQUIPPED WITH KOMTRAX.....2112
BASIC PRECAUTIONS.....2112
INDEX.....2114
TEN00407-02 - Wheel Loader WA200PZ-6 Operation & Maintenance Manual.....2118
COVER.....2118
FOREWORD.....2119
BEFORE READING THIS MANUAL.....2120
SAFETY INFORMATION.....2121
INTRODUCTION.....2122
USE OF MACHINE.....2122
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.....2122
VISIBILITY FROM OPERATOR'S SEAT.....2122
NECESSARY INFORMATION.....2123
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....2123
EPA REGULATIONS, ENGINE NUMBER PLATE.....2123
POSITION OF SERVICE METER.....2124
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....2124
CONTENTS.....2125
SAFETY.....2129
SAFETY.....2130
SAFETY LABELS.....2133
LOCATION OF SAFETY LABELS.....2133
SAFETY LABELS.....2134
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.....2140
PRECAUTIONS BEFORE STARTING OPERATION.....2140
PREPARATIONS FOR SAFE OPERATION.....2140
FIRE PREVENTION.....2142
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.....2143
DO NOT GET CAUGHT IN ARTICULATING PORTION.....2146
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES.....2146
UNAUTHORIZED MODIFICATION.....2146
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS.....2146
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING.....2147
PRECAUTIONS FOR OPERATION.....2148
PRECAUTIONS FOR JOBSITE.....2148
STARTING ENGINE.....2150
OPERATION.....2152
TRANSPORTATION.....2159
TOWING.....2160
PRECAUTIONS FOR MAINTENANCE.....2161
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE.....2161
PRECAUTIONS FOR INSPECTION AND MAINTENANCE.....2166
TIRES.....2171
OPERATION.....2173
GENERAL VIEW.....2174
GENERAL VIEW OF MACHINE.....2174
GENERAL VIEW OF CONTROLS AND GAUGES.....2175
EXPLANATION OF COMPONENTS.....2177
MACHINE MONITOR.....2177
SWITCHES.....2214
CONTROL LEVERS, PEDALS.....2228
STEERING TILT LOCK LEVER.....2233
CAP AND COVER WITH LOCK.....2233
FRAME LOCK BAR.....2234
TOWING PIN.....2235
GREASE PUMP.....2235
OPENING, CLOSING CAB DOORS, WINDOWS.....2236
FUSE.....2240
SLOW BLOW FUSE.....2242
POWER OUTLET.....2243
STORAGE BOX.....2243
AM/FM RADIO-CASSETTE STEREO.....2244
AIR CONDITIONER.....2252
HANDLING CAB WIPER.....2259
OPERATION.....2260
CHECK BEFORE STARTING ENGINE, ADJUST.....2260
STARTING ENGINE.....2279
CHECKS AFTER STARTING ENGINE.....2283
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....2284
STOPPING ENGINE.....2287
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE.....2288
TURNING.....2294
OPERATION OF WORK EQUIPMENT.....2296
HANDLING HYDRAULIC QUICK COUPLER.....2298
WORK POSSIBLE USING WHEEL LOADER.....2302
PRECAUTIONS FOR OPERATION.....2308
ADJUSTING WORK EQUIPMENT POSTURE.....2310
PARKING MACHINE.....2313
CHECKS AFTER COMPLETION OF OPERATION.....2315
LOCKING.....2315
HANDLING THE TIRES.....2316
TRANSPORTATION.....2318
TRANSPORTATION PROCEDURE.....2318
LOADING, UNLOADING WORK WITH TRAILERS.....2318
LIFTING MACHINE.....2322
COLD WEATHER OPERATION.....2324
PRECAUTIONS FOR LOW TEMPERATURE.....2324
PRECAUTIONS AFTER COMPLETION OF WORK.....2325
AFTER COLD WEATHER.....2325
LONG-TERM STORAGE.....2326
BEFORE STORAGE.....2326
DURING STORAGE.....2326
AFTER STORAGE.....2326
TROUBLESHOOTING.....2327
WHEN MACHINE RUNS OUT OF FUEL.....2327
METHOD OF TOWING MACHINE.....2327
IF BATTERY IS DISCHARGED.....2329
OTHER TROUBLE.....2332
MAINTENANCE.....2337
GUIDES TO MAINTENANCE.....2338
OUTLINES OF SERVICE.....2340
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....2340
OUTLINE OF ELECTRIC SYSTEM.....2343
WEAR PARTS.....2344
WEAR PARTS LIST.....2344
RECOMMENDED FUEL, COOLANT, AND LUBRICANT.....2345
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....2346
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.....2347
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....2348
TORQUE LIST.....2348
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....2349
MAINTENANCE SCHEDULE CHART.....2350
MAINTENANCE SCHEDULE CHART.....2350
SERVICE PROCEDURE.....2352
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE).....2352
INITIAL 250 HOURS SERVICE.....2352
INITIAL 1000 HOURS SERVICE.....2352
WHEN REQUIRED.....2353
CHECK BEFORE STARTING.....2380
EVERY 50 HOURS SERVICE.....2381
EVERY 100 HOURS SERVICE.....2382
EVERY 250 HOURS SERVICE.....2385
EVERY 500 HOURS SERVICE.....2391
EVERY 1000 HOURS SERVICE.....2395
EVERY 2000 HOURS SERVICE.....2401
EVERY 4000 HOURS SERVICE.....2408
EVERY 8000 HOURS SERVICE.....2410
SPECIFICATIONS.....2411
SPECIFICATIONS.....2412
ATTACHMENTS, OPTIONS.....2415
SELECTING BUCKET AND TIRES.....2416
HANDLING FORK TOOL.....2417
EXPLANATION OF COMPONENTS.....2417
OPERATION.....2418
METHOD OF USING 3 LEVERS.....2421
EXPLANATION OF COMPONENTS.....2421
HANDLING MACHINES EQUIPPED WITH KOMTRAX.....2423
BASIC PRECAUTIONS.....2423
INDEX.....2425
Komatsu Wheel Loader WA200, WA200PZ Repair Service Manual
