Komatsu ecot3 WA200-6 Install guide

WHEEL LOADER
SEN03862-05
WA200
-6
WA200PZ
-6
SERIAL NUMBERS
WA200- 70001
WA200PZ-70001
and up

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WA200, 200PZ-6 00-100 1
SEN03871-05
WHEEL LOADER
WA200-6 
WA200PZ-6
Machine model Serial number
WA200-6 70001 and up
WA200PZ-6 70001 and up
00 Index and foreword 00
100 Index
Composition of shop manual ..................................................................................................................................2
Table of contents .....................................................................................................................................................4
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SEN03871-05
00-100 2 WA200, 200PZ-6
Composition of shop manual
100 Index
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q:New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN03862-05
00 Index and foreword SEN03863-05
100 Index SEN03871-05
q
200 Foreword and general information SEN03872-00
01 Specification SEN03864-00
100 Specification and technical data SEN03873-00
10 Structure, function and maintenance standard SEN03865-00
100 Engine and cooling system SEN03874-00
200 Power train SEN03875-00
300 Steering system SEN03876-00
400 Brake system SEN03877-00
500 Undercarriage and frame SEN03878-00
600 Hydraulic system SEN03879-00
700 Work equipment SEN03880-00
800 Cab and its attachments SEN03881-00
910 Electrical system, Part 1 SEN03882-00
920 Electrical system, Part 2 SEN03883-00
20 Standard value table SEN03866-01
100 Standard service value table SEN03884-01
30 Testing and adjusting SEN03867-04
110 Testing and adjusting, Part 1 SEN03885-02
q
120 Testing and adjusting, Part 2 SEN03886-03 q
130 Testing and adjusting, Part 3 SEN03887-02
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SEN03871-05
WA200, 200PZ-6 00-100 3
Composition of shop manual
100 Index
40 Troubleshooting SEN03868-02
100 Failure code table and fuse locations SEN03888-01
200 General information on troubleshooting SEN03889-01
310 Troubleshooting by failure code (Display of code), Part 1 SEN03890-01
320 Troubleshooting by failure code (Display of code), Part 2 SEN03891-01
330 Troubleshooting by failure code (Display of code), Part 3 SEN03892-01
340 Troubleshooting by failure code (Display of code), Part 4 SEN03893-01
350 Troubleshooting by failure code (Display of code), Part 5 SEN03894-01
360 Troubleshooting by failure code (Display of code), Part 6 SEN03895-01
370 Troubleshooting by failure code (Display of code), Part 7 SEN03896-00
400 Troubleshooting of electrical system (E-mode) SEN03897-02
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN03898-01
600 Troubleshooting of engine (S-mode) SEN03899-01
50 Disassembly and assembly SEN03869-02
100 General information on disassembly and assembly SEN03900-01
200 Engine and cooling system SEN03901-01
310 Power train, Part 1 SEN03902-00
320 Power train, Part 2 SEN03903-00
400 Undercarriage and frame SEN03904-01
q
500 Hydraulic system SEN03905-00
600 Work equipment SEN03906-00
700 Cab and its attachments SEN03907-00
800 Electrical system SEN03908-00
90 Diagrams and drawings SEN03870-01
100 Hydraulic diagrams and drawings SEN03909-00
200 Electrical diagrams and drawings SEN03910-01
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SEN03871-05
00-100 4 WA200, 200PZ-6
Table of contents
100 Index
Table of contents 1
00 Index and foreword
100 Index SEN03871-05
Composition of shop manual......................................................................................................................... 2
Table of contents........................................................................................................................................... 4
200 Foreword and general information SEN03872-00
Safety notice ................................................................................................................................................. 2
How to read the shop manual....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN03873-00
Specification dimension drawing................................................................................................................... 3
Specifications................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
10 Structure, function and maintenance standard
100 Engine and cooling system SEN03874-00
Engine mount and transfer mount................................................................................................................. 2
Damper ......................................................................................................................................................... 3
Cooling system.............................................................................................................................................. 4
Cooling system hydraulic piping diagram...................................................................................................... 5
Cooling fan motor.......................................................................................................................................... 7
200 Power train SEN03875-00
Power train.................................................................................................................................................... 3
Power train system diagram.......................................................................................................................... 4
Drive shaft..................................................................................................................................................... 6
HST hydraulic piping diagram....................................................................................................................... 7
HST pump..................................................................................................................................................... 8
HST motor..................................................................................................................................................... 16
Transfer......................................................................................................................................................... 22
Clutch solenoid valve.................................................................................................................................... 33
Axle............................................................................................................................................................... 34
Differential..................................................................................................................................................... 36
Torque proportioning differential.................................................................................................................... 41
Limited slip differential................................................................................................................................... 44
Final drive...................................................................................................................................................... 48
300 Steering system SEN03876-00
Steering piping diagram................................................................................................................................ 3
Steering column ............................................................................................................................................ 4
Priority valve.................................................................................................................................................. 5
Orbit-roll valve............................................................................................................................................... 8
2-way restrictor valve.................................................................................................................................... 16
Cushion valve................................................................................................................................................ 17
Steering cylinder............................................................................................................................................ 18
Emergency steering piping diagram.............................................................................................................. 20
Emergency steering valve............................................................................................................................. 21
Steering relief valve....................................................................................................................................... 24
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SEN03871-05
WA200, 200PZ-6 00-100 5
Table of contents
100 Index
400 Brake system SEN03877-00
Brake piping diagram..................................................................................................................................... 3
Charge valve ................................................................................................................................................. 4
Brake valve.................................................................................................................................................... 8
Inching valve.................................................................................................................................................. 12
Accumulator (for brake)................................................................................................................................. 13
Slack adjuster................................................................................................................................................ 14
Brake............................................................................................................................................................. 16
Parking brake control..................................................................................................................................... 21
Parking brake ................................................................................................................................................ 22
500 Undercarriage and frame SEN03878-00
Axle mount and center hinge pin................................................................................................................... 2
Tires............................................................................................................................................................... 7
600 Hydraulic system SEN03879-00
Work equipment hydraulic piping diagram .................................................................................................... 2
Work equipment control lever linkage ........................................................................................................... 6
Hydraulic tank................................................................................................................................................ 10
4-gear pump.................................................................................................................................................. 12
Work equipment control valve ....................................................................................................................... 15
PPC valve...................................................................................................................................................... 39
Lock valve...................................................................................................................................................... 54
Accumulator (for PPC circuit)........................................................................................................................ 55
Bypass valve ................................................................................................................................................. 56
Quick coupler solenoid valve......................................................................................................................... 59
ECSS valve ................................................................................................................................................... 60
Accumulator (for ECSS)................................................................................................................................ 62
700 Work equipment SEN03880-00
Work equipment linkage................................................................................................................................ 2
Bucket............................................................................................................................................................ 6
Bucket positioner and boom kick-out............................................................................................................. 10
Work equipment cylinder............................................................................................................................... 23
800 Cab and its attachments SEN03881-00
Cab................................................................................................................................................................ 3
Air conditioner................................................................................................................................................ 4
910 Electrical system, Part 1 SEN03882-00
Machine monitor system................................................................................................................................ 2
Machine monitor............................................................................................................................................ 6
920 Electrical system, Part 2 SEN03883-00
Electrical system (HST controller system)..................................................................................................... 2
HST controller................................................................................................................................................ 18
ECSS system ................................................................................................................................................ 20
KOMTRAX system ........................................................................................................................................ 22
Engine starting circuit .................................................................................................................................... 24
Engine stopping circuit .................................................................................................................................. 26
Preheating circuit........................................................................................................................................... 27
Engine output derating function..................................................................................................................... 28
Automatic warm-up function.......................................................................................................................... 28
Parking brake circuit...................................................................................................................................... 29
Coupler plunger control system..................................................................................................................... 32
Multi-function knob ........................................................................................................................................ 33
Max. traction switch....................................................................................................................................... 34
Sensor........................................................................................................................................................... 35
20 Standard value table
100 Standard service value table SEN03884-01
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
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SEN03871-05
00-100 6 WA200, 200PZ-6
Table of contents
100 Index
30 Testing and adjusting
110 Testing and adjusting, Part 1 SEN03885-02
Tools for testing, adjusting, and troubleshooting........................................................................................... 2
Sketches of special tools............................................................................................................................... 7
Measuring engine speed............................................................................................................................... 8
Measuring exhaust gas color........................................................................................................................ 10
Adjusting valve clearance ............................................................................................................................. 11
Measuring compression pressure................................................................................................................. 13
Measuring blow-by pressure......................................................................................................................... 16
Testing engine oil pressure ........................................................................................................................... 17
Measuring intake air (boost) pressure........................................................................................................... 18
Handling fuel system equipment................................................................................................................... 20
Releasing residual pressure in fuel system................................................................................................... 20
Measuring fuel pressure................................................................................................................................ 21
Measuring fuel return rate and leakage ........................................................................................................ 23
Bleeding air from fuel circuit.......................................................................................................................... 27
Checking leakage in fuel system................................................................................................................... 28
Handling cylinder cut-out mode operation..................................................................................................... 29
Handling no-injection cranking operation...................................................................................................... 29
Handling controller voltage circuit ................................................................................................................. 30
Check of muffler and muffler stack for looseness and damage .................................................................... 30
Check of muffler function .............................................................................................................................. 31
Check of installed condition of cylinder head and manifolds......................................................................... 31
Check of engine piping for damage and looseness...................................................................................... 32
Testing and adjusting air conditioner compressor belt tension...................................................................... 32
Replacing alternator belt............................................................................................................................... 33
120 Testing and adjusting, Part 2 SEN03886-03
Checking operating force of accelerator pedal.............................................................................................. 3
Checking directional lever............................................................................................................................. 4
Testing and adjusting HSToil pressure......................................................................................................... 5
Testing clutch control pressure...................................................................................................................... 10
Testing and adjusting steering wheel ............................................................................................................ 11
Testing and adjusting steering oil pressure................................................................................................... 13
Bleeding air from steering circuit................................................................................................................... 15
Testing hydraulic fan ..................................................................................................................................... 16
Measuring brake pedal.................................................................................................................................. 18
Testing and adjusting brake pedal linkage.................................................................................................... 19
Measuring brake performance...................................................................................................................... 20
Testing and adjusting accumulator charge pressure..................................................................................... 21
Testing wheel brake oil pressure................................................................................................................... 23
Testing wear of brake disc............................................................................................................................. 26
Bleeding air from wheel brake circuit............................................................................................................ 27
Releasing residual pressure in brake accumulator circuit............................................................................. 28
Testing parking brake performance............................................................................................................... 29
Testing and adjusting parking brake control cable........................................................................................ 30
Measuring and adjusting work equipment control lever................................................................................ 31
Testing and adjusting work equipment hydraulic pressure............................................................................ 32
Testing work equipment PPC oil pressure .................................................................................................... 33
Bleeding air from hydraulic circuit ................................................................................................................. 35
Releasing remaining pressure in hydraulic circuit......................................................................................... 36
Testing and adjusting bucket positioner........................................................................................................ 37
Testing and adjusting boom kick-out switch.................................................................................................. 39
Checking proximity switch operation pilot lamp ............................................................................................ 40
Procedure for testing diodes......................................................................................................................... 41
Preparation work for troubleshooting for electric system.............................................................................. 43
Starting KOMTRAX terminal operations........................................................................................................ 47
Indicator lamps of KOMTRAX terminal......................................................................................................... 51
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SEN03871-05
WA200, 200PZ-6 00-100 7
Table of contents
100 Index
130 Testing and adjusting, Part 3 SEN03887-02
Adjusting machine monitor............................................................................................................................ 2
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3
Special functions of machine monitor (EMMS).............................................................................................. 5
Pm clinic inspection chart.............................................................................................................................. 59
40 Troubleshooting
100 Failure code table and fuse locations SEN03888-01
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting SEN03889-01
Points to remember when troubleshooting.................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Testing before troubleshooting ...................................................................................................................... 4
Classification and procedures of troubleshooting.......................................................................................... 5
Information contained in troubleshooting table.............................................................................................. 8
Connection table for connector pin numbers................................................................................................. 10
T- branch box and T- branch adapter table ................................................................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 SEN03890-01
Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2
Failure code [6091NX] HST filter: Clogging................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection charge/Low charge voltage ....... 8
Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 10
Failure code [B@BCNS] Engine: Overheat................................................................................................... 11
Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 14
Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 15
320 Troubleshooting by failure code (Display of code), Part 2 SEN03891-01
Failure code [CA111] Abnormality in engine controller.................................................................................. 3
Failure code [CA115] Engine Ne or Bkup speed sensor error.......................................................................4
Failure code [CA122] Charge pressure sensor high error............................................................................. 6
Failure code [CA123] Charge pressure sensor low error.............................................................................. 8
Failure code [CA131] Throttle sensor high error ........................................................................................... 10
Failure code [CA132] Throttle sensor low error............................................................................................. 12
Failure code [CA144] Coolant sensor high error........................................................................................... 14
Failure code [CA145] Coolant sensor low error............................................................................................. 16
Failure code [CA153] Charge temperature sensor high error .......................................................................18
Failure code [CA154] Charge temperature sensor low error......................................................................... 20
Failure code [CA155] Derating of speed by abnormally high charge temperature........................................ 22
Failure code [CA187] Sensor power supply 2 low error................................................................................ 24
Failure code [CA221] Atmospheric pressure sensor high error.....................................................................26
Failure code [CA222] Atmospheric sensor low error..................................................................................... 28
Failure code [CA227] Sensor power supply 2 high error............................................................................... 30
Failure code [CA234] Engine overspeed....................................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error.......................................................................... 32
Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 33
Failure code [CA272] IMV (IMA) Disconnection............................................................................................ 34
Failure code [CA322] Injector #1 open/short error ........................................................................................ 36
Failure code [CA324] Injector #3 open/short error ........................................................................................ 38
Failure code [CA331] Injector #2 open/short error ........................................................................................ 40
Failure code [CA332] Injector #4 open/short error ........................................................................................ 42
Failure code [CA342] Calibration code inconsistency................................................................................... 44
Failure code [CA351] Injectors drive circuit error .......................................................................................... 46
Failure code [CA352] Sensor power supply 1 low error................................................................................ 48
Failure code [CA386] Sensor power supply 1 high error............................................................................... 50
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SEN03871-05
00-100 8 WA200, 200PZ-6
Table of contents
100 Index
330 Troubleshooting by failure code (Display of code), Part 3 SEN03892-01
Failure code [CA428] Abnormally high level in water sensor........................................................................ 4
Failure code [CA429] Abnormally low level in water sensor......................................................................... 6
Failure code [CA431] Idle validation switch error.......................................................................................... 8
Failure code [CA432] Idle validation action error.......................................................................................... 12
Failure code [CA435] Engine oil pressure switch error................................................................................. 16
Failure code [CA441] Battery voltage low error ............................................................................................ 17
Failure code [CA442] Battery voltage high error........................................................................................... 20
Failure code [CA449] Common rail pressure high error 2............................................................................. 22
Failure code [CA451] Common rail pressure sensor high error.................................................................... 24
Failure code [CA452] Common rail pressure sensor low error..................................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature....................................... 28
Failure code [CA553] Common rail pressure high error 1............................................................................. 29
Failure code [CA559] Supply pump pressure very low error......................................................................... 30
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32
Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 34
Failure code [CA757] All continuous data lost error...................................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40
Failure code [CA2185] Throttle sensor supply voltage high error.................................................................42
Failure code [CA2186] Throttle sensor power supply low error....................................................................44
Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 46
Failure code [CA2311] Abnormality in IMV (IMA) solenoid........................................................................... 48
Failure code [CA2555] Intake heater relay disconnection error.................................................................... 50
Failure code [CA2556] Intake heater relay short circuit error........................................................................ 52
340 Troubleshooting by failure code (Display of code), Part 4 SEN03893-01
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2
Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6
Failure code [D1B0KB] HST safety relay: Ground fault................................................................................ 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality.................................................... 22
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 24
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............ 32
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection..................................................... 37
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43
350 Troubleshooting by failure code (Display of code), Part 5 SEN03894-01
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 2
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short........................................ 12
Failure code [DDB6KB] Parking brake indicator signal: Ground fault........................................................... 14
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch
(intermediate switch): Trouble................................................................................................................. 16
Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 22
Failure code [DDD7KY] Travel speed control dial signal: Hot short.............................................................. 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection............................................ 26
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