Related Manuals for Komatsu ecot3 WA200-6
Summary of Contents for Komatsu ecot3 WA200-6
- Page 1 SEN03862-05 WHEEL LOADER WA200 WA200PZ WA200- 70001 SERIAL NUMBERS and up WA200PZ- 70001...
- Page 2 Find manuals at https://best-manuals.com...
- Page 3 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 100 Index Composition of shop manual..........................2 Table of contents ..............................4 WA200, 200PZ-6 00-100 Find manuals at https://best-manuals.com...
- Page 4 100 Index SEN03871-05 Composition of shop manual Composition of shop manual 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.
- Page 5 100 Index SEN03871-05 Composition of shop manual 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...
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Page 6: Table Of Contents
100 Index SEN03871-05 Table of contents Table of contents 00 Index and foreword 100 Index SEN03871-05 Composition of shop manual......................... Table of contents ............................200 Foreword and general information SEN03872-00 Safety notice ..............................How to read the shop manual ........................Explanation of terms for maintenance standard.................... - Page 7 100 Index SEN03871-05 Table of contents 400 Brake system SEN03877-00 Brake piping diagram............................. Charge valve ..............................Brake valve..............................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 ........................
- Page 8 100 Index SEN03871-05 Table of contents 30 Testing and adjusting 110 Testing and adjusting, Part 1 SEN03885-02 Tools for testing, adjusting, and troubleshooting ................... Sketches of special tools..........................Measuring engine speed..........................Measuring exhaust gas color ........................10 Adjusting valve clearance ..........................11 Measuring compression pressure .........................
- Page 9 100 Index SEN03871-05 Table of contents 130 Testing and adjusting, Part 3 SEN03887-02 Adjusting machine monitor ..........................Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ......Special functions of machine monitor (EMMS)....................Pm clinic inspection chart ..........................59 40 Troubleshooting 100 Failure code table and fuse locations SEN03888-01...
- Page 10 100 Index SEN03871-05 Table of contents 330 Troubleshooting by failure code (Display of code), Part 3 SEN03892-01 Failure code [CA428] Abnormally high level in water sensor................ Failure code [CA429] Abnormally low level in water sensor ................. Failure code [CA431] Idle validation switch error..................Failure code [CA432] Idle validation action error ..................
- Page 11 100 Index SEN03871-05 Table of contents Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short..........28 Failure code [DDK3KB] Directional selector switch: Ground fault ..............30 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault..............32 Failure code [DDK6KY] FNR lever: Hot short....................36 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ........
- Page 12 100 Index SEN03871-05 Table of contents E-18 Backup lamp does not light or it keeps lighting up ................78 E-19 Backup alarm does not sound or it keeps sounding................81 E-20 Horn does not sound or it keeps sounding ................... 84 E-21 Alarm buzzer does not sound or it keeps sounding................
- Page 13 100 Index SEN03871-05 Table of contents 50 Disassembly and assembly 100 General information on disassembly and assembly SEN03900-01 How to read this manual..........................Coating materials list ............................. Special tool list............................... Sketches of special tools ..........................11 200 Engine and cooling system SEN03901-01 Removal and installation of fuel supply pump assembly ................
- Page 14 100 Index SEN03871-05 Table of contents 90 Diagrams and drawings 100 Hydraulic diagrams and drawings SEN03909-00 Hydraulic circuit diagram..........................200 Electrical diagrams and drawings SEN03910-01 Electrical circuit diagram ..........................Connector list and stereogram ........................23 00-100 WA200, 200PZ-6...
- Page 15 100 Index SEN03871-05 Table of contents WA200, 200PZ-6 00-100...
- Page 16 SEN03871-05 WA200-6, WA200PZ-6 Wheel loader Form No. SEN03871-05 ©2017 KOMATSU All Rights Reserved Printed in Japan 10-17 (01) 00-100...
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Page 17: 00 Index And Foreword
SEN03872-00 WHEEL LOADER WA200-6 WA200PZ-6 Machine model Serial number WA200-6 70001 and up WA200PZ-6 70001 and up 00 Index and foreword 200 Foreword and general information 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 ................... -
Page 18: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. -
Page 19: Specification Dimension Drawing
200 Foreword and general information SEN03872-00 Safety notice When disassembling or assembling, sup- When removing piping, stop the fuel or oil port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips stands before starting work. onto the floor, wipe it up immediately. -
Page 20: Table Of Contents
200 Foreword and general information SEN03872-00 Safety notice Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is seen well from the operator's seat and where he can see the working condition easily. -
Page 21: Cooling System Hydraulic Piping Diagram
200 Foreword and general information SEN03872-00 Safety notice If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again. -
Page 22: Drive Shaft
200 Foreword and general information SEN03872-00 Safety notice Precautions for disconnecting and con- necting hoses and tubes in air conditioner circuit Disconnection Collect the air conditioner refriger- ant (R134a) from the air condi- tioner circuit in advance. a Ask professional traders for collecting and filling operation of refrigerant (R134a). -
Page 23: How To Read The Shop Manual
This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. WA200, 200PZ-6... -
Page 24: Weight Table
200 Foreword and general information SEN03872-00 How to read the shop manual Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. -
Page 25: Explanation Of Terms For Maintenance Standard
200 Foreword and general information SEN03872-00 Explanation of terms for maintenance standard Explanation of terms for maintenance standard The maintenance standard values necessary for judgment of products and parts are described by the follow- ing terms. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. -
Page 26: Table Of Fuel, Coolant And Lubricants
200 Foreword and general information SEN03872-00 Explanation of terms for maintenance standard Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit. -
Page 27: Handling Of Electric Equipment And Hydraulic Component
200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. - Page 28 200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring...
- Page 29 200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
- Page 30 200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins.
- Page 31 200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2).
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Page 32: Hst Motor
200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. -
Page 33: Cushion Valve
200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. -
Page 34: Steering Cylinder
200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. - Page 35 200 Foreword and general information SEN03872-00 Handling of electric equipment and hydraulic component Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
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Page 36: Handling Of Connectors Newly Used For Engines
200 Foreword and general information SEN03872-00 Handling of connectors newly used for engines Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 107 – 170, 12V140 engine 107E-1 Various temperature sensors 114E-3 Example) -
Page 37: Emergency Steering Valve
200 Foreword and general information SEN03872-00 Handling of connectors newly used for engines Push lock type 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. -
Page 38: Transfer
200 Foreword and general information SEN03872-00 Handling of connectors newly used for engines 125 – 170, 12V140 engine Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pullout connector (5) in the direction of the Example) arrow. -
Page 39: How To Read Electric Wire Code
200 Foreword and general information SEN03872-00 How to read electric wire code How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols. -
Page 40: Steering Relief Valve
200 Foreword and general information SEN03872-00 How to read electric wire code Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51... - Page 41 200 Foreword and general information SEN03872-00 How to read electric wire code Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue &...
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Page 42: Precautions When Carrying Out Operation
200 Foreword and general information SEN03872-00 Precautions when carrying out operation Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. -
Page 43: Cooling System
200 Foreword and general information SEN03872-00 Precautions when carrying out operation Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. - Page 44 200 Foreword and general information SEN03872-00 Precautions when carrying out operation Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
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Page 45: Method Of Disassembling And Connecting Push-Pull Type Coupler
200 Foreword and general information SEN03872-00 Method of disassembling and connecting push-pull type coupler Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. - Page 46 200 Foreword and general information SEN03872-00 Method of disassembling and connecting push-pull type coupler Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise).
- Page 47 200 Foreword and general information SEN03872-00 Method of disassembling and connecting push-pull type coupler Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal por-...
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Page 48: Standard Tightening Torque Table
200 Foreword and general information SEN03872-00 Standard tightening torque table Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) a The following table corresponds to the bolts in Fig. -
Page 49: Clutch Solenoid Valve
200 Foreword and general information SEN03872-00 Standard tightening torque table Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 –... -
Page 50: Axle
200 Foreword and general information SEN03872-00 Standard tightening torque table Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. - Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...