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SEN03081-02

WHEEL LOADER

WA200 -6
SERIAL NUMBERS 70001 and up
SEN03090-02

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4

WA200-6 1
SEN03090-02 00 Index and foreword

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 SEN03081-02

00 Index and foreword SEN03082-02


Index SEN03090-02 q
Foreword and general information SEN03091-00

01 Specification SEN03083-00
Specification and technical data SEN03092-00

10 Structure, function and maintenance standard SEN03084-00


Engine and cooling system SEN03250-00
Power train SEN03251-00
Steering system SEN03252-00
Brake system SEN03253-00
Undercarriage and frame SEN03254-00
Hydraulic system SEN03255-00
Work equipment SEN03256-00
Cab and its attachments SEN03257-00
Electrical system, Part 1 SEN03258-00
Electrical system, Part 2 SEN03259-00

20 Standard value table SEN03085-00


Standard service value table SEN03731-00

30 Testing and adjusting SEN03086-00


Testing and adjusting, Part 1 SEN03732-00
Testing and adjusting, Part 2 SEN03733-00
Testing and adjusting, Part 3 SEN03734-00

40 Troubleshooting SEN03087-00
Failure code table and fuse locations SEN03735-00
General information on troubleshooting SEN03736-00
Troubleshooting by failure code (Display of code), Part 1 SEN03737-00
Troubleshooting by failure code (Display of code), Part 2 SEN03738-00
Troubleshooting by failure code (Display of code), Part 3 SEN03739-00

2 WA200-6
00 Index and foreword SEN03090-02

Troubleshooting by failure code (Display of code), Part 4 SEN03740-00


Troubleshooting by failure code (Display of code), Part 5 SEN03741-00
Troubleshooting by failure code (Display of code), Part 6 SEN03742-00
Troubleshooting by failure code (Display of code), Part 7 SEN03743-00
Troubleshooting of electrical system (E-mode) SEN03744-00
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03745-00
Troubleshooting of engine (S-mode) SEN03746-00

50 Disassembly and assembly SEN03088-00


General information on disassembly and assembly SEN03786-00 Q
Engine and cooling system SEN03787-00 Q
Power train, Part 1 SEN03788-00 Q
Power train, Part 2 SEN03789-00 Q
Undercarriage and frame SEN03790-00 Q
Hydraulic system SEN03791-00 Q
Work equipment SEN03792-00 Q
Cab and its attachments SEN03793-00 Q
Electrical system SEN03794-00 Q

90 Diagrams and drawings SEN03089-01


Hydraulic diagrams and drawings SEN03093-00
Electrical diagrams and drawings SEN03094-01

WA200-6 3
SEN03090-02 00 Index and foreword

Table of contents 1

00 Index and foreword


Index SEN03090-02
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN03091-00
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
Specification and technical data SEN03092-00
Specification dimension drawing ................................................................................................. 3
Specifications .............................................................................................................................. 4
Weight table ................................................................................................................................ 8
Table of fuel, coolant and lubricants ............................................................................................ 10

10 Structure, function and maintenance standard


Engine and cooling system SEN03250-00
Engine mount and transfer mount ............................................................................................... 2
Damper........................................................................................................................................ 3
Cooling system............................................................................................................................ 4
Cooling system hydraulic piping diagram.................................................................................... 5
Cooling fan motor ........................................................................................................................ 7
Power train SEN03251-00
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
Steering system SEN03252-00
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

4 WA200-6
00 Index and foreword SEN03090-02

Brake system SEN03253-00


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
Undercarriage and frame SEN03254-00
Axle mount and center hinge pin................................................................................................. 2
Hydraulic system SEN03255-00
Work equipment hydraulic piping diagram .................................................................................. 2
Work equipment control lever linkage ......................................................................................... 4
Hydraulic tank ............................................................................................................................. 6
4-gear pump................................................................................................................................ 8
Work equipment control valve ..................................................................................................... 11
PPC valve ................................................................................................................................... 27
Lock valve ................................................................................................................................... 36
Accumulator (for PPC circuit)...................................................................................................... 37
ECSS valve ................................................................................................................................. 38
Accumulator (for ECSS).............................................................................................................. 40
Work equipment SEN03256-00
Work equipment linkage.............................................................................................................. 2
Bucket ......................................................................................................................................... 4
Bucket positioner and boom kick-out .......................................................................................... 6
Work equipment cylinder............................................................................................................. 12
Cab and its attachments SEN03257-00
Cab.............................................................................................................................................. 3
Air conditioner ............................................................................................................................. 4
Electrical system, Part 1 SEN03258-00
Machine monitor system ............................................................................................................. 2
Machine monitor.......................................................................................................................... 6
Electrical system, Part 2 SEN03259-00
Electrical system (HST controller system) .................................................................................. 2
HST controller ............................................................................................................................. 18
ECSS system .............................................................................................................................. 19
KOMTRAX system ...................................................................................................................... 20
Engine starting circuit .................................................................................................................. 22
Engine stopping circuit ................................................................................................................ 24
Preheating circuit ........................................................................................................................ 25
Engine output derating function .................................................................................................. 26
Automatic warm-up function........................................................................................................ 26
Parking brake circuit.................................................................................................................... 28
Max. traction switch..................................................................................................................... 30
Sensor......................................................................................................................................... 31

20 Standard value table


Standard service value table SEN03731-00
Standard service value table for engine ...................................................................................... 2
Standard service value table for chassis ..................................................................................... 3

WA200-6 5
SEN03090-02 00 Index and foreword

30 Testing and adjusting


Testing and adjusting, Part 1 SEN03732-00
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed ............................................................................................................. 8
Measuring exhaust gas color ...................................................................................................... 10
Adjusting valve clearance............................................................................................................ 12
Measuring compression pressure ............................................................................................... 14
Measuring blow-by pressure ....................................................................................................... 17
Testing engine oil pressure.......................................................................................................... 18
Measuring intake air (boost) pressure......................................................................................... 19
Handling fuel system equipment ................................................................................................. 21
Releasing residual pressure in fuel system................................................................................. 21
Measuring fuel pressure.............................................................................................................. 22
Measuring fuel return rate and leakage....................................................................................... 24
Bleeding air from fuel circuit ........................................................................................................ 28
Testing leakage in fuel system .................................................................................................... 29
Handling reduced cylinder mode operation................................................................................. 30
Handling no-injection cranking operation .................................................................................... 30
Handling controller voltage circuit ............................................................................................... 31
Check of muffler and muffler stack for looseness and damage................................................... 31
Check of muffler function............................................................................................................. 32
Check of installed condition of cylinder head and manifolds....................................................... 32
Check of engine piping for damage and looseness .................................................................... 33
Testing and adjusting air conditioner compressor belt tension.................................................... 33
Replacing alternator belt ............................................................................................................. 34
Testing and adjusting, Part 2 SEN03733-00
Checking operating force of accelerator pedal............................................................................ 3
Checking directional lever ........................................................................................................... 4
Testing and adjusting HST oil pressure....................................................................................... 5
Testing clutch control pressure.................................................................................................... 9
Testing and adjusting steering wheel .......................................................................................... 10
Testing and adjusting steering oil pressure ................................................................................. 12
Bleeding air from steering circuit ................................................................................................. 14
Testing hydraulic fan.................................................................................................................... 15
Measuring brake pedal................................................................................................................ 17
Testing and adjusting brake pedal linkage .................................................................................. 18
Measuring brake performance .................................................................................................... 19
Testing and adjusting accumulator charge pressure ................................................................... 20
Testing wheel brake oil pressure ................................................................................................. 22
Testing wear of brake disc........................................................................................................... 25
Bleeding air from wheel brake circuit .......................................................................................... 26
Releasing residual pressure in brake accumulator circuit ........................................................... 27
Testing parking brake performance ............................................................................................. 28
Testing and adjusting parking brake control cable ...................................................................... 29
Measuring and adjusting work equipment control lever .............................................................. 30
Testing and adjusting work equipment hydraulic pressure.......................................................... 31
Testing work equipment PPC oil pressure................................................................................... 32
Bleeding air from hydraulic circuit ............................................................................................... 34
Releasing remaining pressure in hydraulic circuit ....................................................................... 35
Testing and adjusting bucket positioner ...................................................................................... 36
Testing and adjusting of boom kick-out switch ............................................................................ 38
Checking proximity switch operation pilot lamp........................................................................... 39
Procedure for testing diodes ....................................................................................................... 40
Preparation work for troubleshooting for electric system ............................................................ 42
Starting KOMTRAX terminal operations...................................................................................... 46
Indicator lamps of KOMTRAX terminal ....................................................................................... 50

6 WA200-6
00 Index and foreword SEN03090-02

Testing and adjusting, Part 3 SEN03734-00


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
Failure code table and fuse locations SEN03735-00
Failure codes table...................................................................................................................... 2
Fuse locations ............................................................................................................................. 8
General information on troubleshooting SEN03736-00
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
Troubleshooting by failure code (Display of code), Part 1 SEN03737-00
Failure code [2G40GZ] Brake: Oil pressure reduction.................................................................. 2
Failure code [6091NX] HST filter: Clogging .................................................................................. 4
Failure code [989FN1] Travel speed: Overrun alarm.................................................................... 5
Failure code [AB00L6] Alternator R system: Hot short ................................................................. 6
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage . 8
Failure code [B@BAZG] Engine: Oil pressure reduction.............................................................. 10
Failure code [B@BCNS] Engine: Overheat .................................................................................. 11
Failure code [B@BCZK] Engine: Low coolant level...................................................................... 12
Failure code [B@C6NS] Front brake: High oil temperature.......................................................... 14
Failure code [B@CRNS] HST: High oil temperature..................................................................... 15
Troubleshooting by failure code (Display of code), Part 2 SEN03738-00
Failure code [CA111] Abnormality in engine controller................................................................ 3
Failure code [CA115] Engine Ne or Bkup speed sensor error .................................................... 4
Failure code [CA122] Charge pressure sensor high error .......................................................... 6
Failure code [CA123] Charge pressure sensor low error............................................................ 8
Failure code [CA131] Throttle sensor high error ......................................................................... 10
Failure code [CA132] Throttle sensor low error .......................................................................... 12
Failure code [CA144] Coolant sensor high error......................................................................... 14
Failure code [CA145] Coolant sensor low error .......................................................................... 16
Failure code [CA153] Charge temperature sensor high error ..................................................... 18
Failure code [CA154] Charge temperature sensor low error ...................................................... 20
Failure code [CA155] Derating of speed by abnormally high charge temperature ..................... 22
Failure code [CA187] Sensor power supply 2 low error .............................................................. 24
Failure code [CA221] Atmospheric pressure sensor high error .................................................. 26
Failure code [CA222] Atmospheric sensor low error................................................................... 28
Failure code [CA227] Sensor power supply 2 high error ............................................................ 30
Failure code [CA234] Engine overspeed .................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error ....................................................... 32
Failure code [CA271] IMV (IMA) Short circuit ............................................................................. 33
Failure code [CA272] IMV (IMA) Disconnection.......................................................................... 34
Failure code [CA322] Injector #1 open/short error ...................................................................... 36
Failure code [CA324] Injector #3 open/short error ...................................................................... 38
Failure code [CA331] Injector #2 open/short error ...................................................................... 40
Failure code [CA332] Injector #4 open/short error ...................................................................... 42
Failure code [CA342] Calibration code inconsistency................................................................. 44
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

WA200-6 7
SEN03090-02 00 Index and foreword

Troubleshooting by failure code (Display of code), Part 3 SEN03739-00


Failure code [CA428] Abnormally high level in water sensor ...................................................... 4
Failure code [CA429] Abnormally low level in water sensor ....................................................... 6
Failure code [CA431] Idle validation switch error ........................................................................ 8
Failure code [CA432] Idle validation action error ........................................................................ 12
Failure code [CA435] Engine oil pressure switch error ............................................................... 16
Failure code [CA441] Battery voltage low error........................................................................... 17
Failure code [CA442] Battery voltage high error ......................................................................... 20
Failure code [CA449] Common rail pressure high error 2........................................................... 22
Failure code [CA451] Common rail pressure sensor high error .................................................. 24
Failure code [CA452] Common rail pressure sensor low error ................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature ..................... 28
Failure code [CA553] Common rail pressure high error 1........................................................... 29
Failure code [CA559] Supply pump pressure very low error....................................................... 30
Failure code [CA689] Engine Ne speed sensor error.................................................................. 32
Failure code [CA731] Engine Bkup speed sensor phase error ................................................... 34
Failure code [CA757] All continuous data lost error .................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error .............................................................. 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................. 40
Failure code [CA2185] Throttle sensor supply voltage high error ............................................... 44
Failure code [CA2186] Throttle sensor power supply low error .................................................. 46
Failure code [CA2249] Supply pump pressure very low error 2.................................................. 48
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ......................................................... 50
Failure code [CA2555] Intake heater relay disconnection error .................................................. 52
Failure code [CA2556] Intake heater relay short circuit error ...................................................... 54
Troubleshooting by failure code (Display of code), Part 4 SEN03740-00
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short.......................................... 4
Failure code [D192KY] ECSS solenoid relay: Hot short.............................................................. 6
Failure code [D1B0KA] HST safety relay: Disconnection............................................................ 8
Failure code [D1B0KB] HST safety relay: Ground fault .............................................................. 10
Failure code [D1B0KY] HST safety relay: Hot short.................................................................... 12
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ........................................... 14
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection ................................ 16
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection............................... 18
Failure code [DAJ0KK] HST controller power supply: Low voltage............................................. 22
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................. 24
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................. 26
Failure code [DAJ1L6] HST controller main power line: Hot short .............................................. 28
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage...................................... 30
Failure code [DAJ2L3] HST controller load power supply holding line:
Hot short in wiring harness................................................................................................... 32
Failure code [DAJ2L4] HST controller load power supply holding line:
Disconnection/Ground fault.................................................................................................. 34
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range ....................................... 36
Failure code [DAJ9KQ] HST controller model selection:
Disagreement of model selection signals............................................................................. 38
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ................................... 39
Failure code [DAJRMA] HST controller: Disagreement in option selection................................. 45
Troubleshooting by failure code (Display of code), Part 5 SEN03741-00
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line ..................... 3
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality................................. 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality................................................. 10
Failure code [DDB6KA] Parking brake switch A: Disconnection/Hot short ................................. 12
Failure code [DDB6KB] Parking brake switch B: 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 switch A: Ground fault..................................................... 18
Failure code [DDB6L4] Parking brake switch B: Disconnection/Hot short .................................. 20

8 WA200-6
00 Index and foreword SEN03090-02

Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ............... 22
Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................ 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection.......................... 26
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault ................................................ 28
Failure code [DDK6KY] FNR lever: Hot short ............................................................................. 32
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering).............. 34
Troubleshooting by failure code (Display of code), Part 6 SEN03742-00
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault .......... 3
Failure code [DF10KB] Travel speed range selector switch: Hot short....................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault............................................ 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.......................................... 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ....................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault.......................... 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short....................................................... 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................ 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short............................................ 18
Failure code [DLT3KX] Travel speed sensor B: Abnormality ...................................................... 20
Failure code [DLT4KX] Travel speed sensor A: Abnormality ...................................................... 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality................................................ 26
Failure code [DV00KY] Alarm buzzer: Hot short......................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault...................................... 30
Failure code [DW26KY] Motor 2 solenoid: Hot short .................................................................. 32
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................. 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault .................... 36
Troubleshooting by failure code (Display of code), Part 7 SEN03743-00
Failure code [DX16KA] Fan EPC solenoid: Disconnection ......................................................... 3
Failure code [DX16KB] Fan EPC solenoid: Ground fault............................................................ 4
Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................. 5
Failure code [DX19KA] Motor 1 solenoid: Disconnection ........................................................... 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault .............................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short ................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection ..................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault........................................................ 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................. 16
Failure code [DXH7KB] Reverse solenoid: Ground fault ............................................................ 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short .......................................... 20
Failure code [DXH8KB] Forward solenoid: Ground fault............................................................. 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short .......................................... 24
Failure code [J141N1] Steering pump: Overrun alarm................................................................ 26
Failure code [M100N1] HST pump: Overrun alarm..................................................................... 26
Failure code [M400N1] Motor 1: Overrun alarm.......................................................................... 27
Troubleshooting of electrical system (E-mode) SEN03744-00
E-1 Engine does not start............................................................................................................ 3
E-2 Preheater does not operate normally ................................................................................... 10
E-3 Defective boom kick-out function and cancellation............................................................... 14
E-4 Defective bucket positioner function and cancellation.......................................................... 18
E-5 Defective lift arm FLOATING holding function and cancellation ........................................... 22
E-6 Travel direction selection system does not function ............................................................. 26
E-7 Wiper does not operate ........................................................................................................ 30
E-8 Windshield washer does not operate ................................................................................... 34
E-9 Headlamp, clearance lamp and tail lamp do not light up or go off........................................ 38
E-10 Working lamp does not light up or go off ............................................................................ 46
E-11 Turn signal lamp and hazard lamp do not light up or go off ................................................ 51
E-12 Brake lamp does not light or it keeps lighting up ................................................................ 58
E-13 Backup lamp does not light or it keeps lighting up ............................................................. 60
E-14 Backup alarm does not sound or it keeps sounding ........................................................... 63
E-15 Horn does not sound or it keeps sounding ......................................................................... 66
E-16 Alarm buzzer does not sound or it keeps sounding............................................................ 68

WA200-6 9
SEN03090-02 00 Index and foreword

E-17 Air conditioner does not operate or stop............................................................................. 70


E-18 The KOMTRAX system does not work properly ................................................................. 73
Troubleshooting of hydraulic and mechanical system (H-mode) SEN03745-00
Method of using troubleshooting chart .......................................................................................... 3
Failure code and cause table ........................................................................................................ 6
H-1 The machine does not start .................................................................................................... 8
H-2 The travel speed is slow ......................................................................................................... 9
H-3 The traction force is weak....................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively........................................... 11
H-5 Speed range is not shifted ...................................................................................................... 12
H-6 The steering wheel does not turn ........................................................................................... 13
H-7 The steering wheel is heavy ................................................................................................... 14
H-8 Steering wheel shakes or jerks............................................................................................... 15
H-9 Machine deviates naturally to one side when traveling .......................................................... 15
H-10 The brake does not work or does not work well ................................................................... 16
H-11 The brake is not released or is dragged ............................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height........................................ 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) .................. 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................. 20
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily.. 21
H-19 The bucket does not tilt back ................................................................................................ 22
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................... 24
H-23 Hydraulic drifts of the bucket occur often.............................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”). 24
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily ...... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy .................. 25
H-27 The ECSS does not operate and machine pitches and bounces......................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) 27
Troubleshooting of engine (S-mode) SEN03746-00
Method of using troubleshooting charts ...................................................................................... 2
S-1 Starting performance is poor................................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly ........................................................................................ 10
S-4 Engine stops during operations ............................................................................................ 11
S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive ........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23

50 Disassembly and assembly


General information on disassembly and assembly SEN03786-00
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Special tool list............................................................................................................................. 7

10 WA200-6
00 Index and foreword SEN03090-02

Sketches of special tools............................................................................................................. 11


Engine and cooling system SEN03787-00
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of fuel injector assembly ..................................................................... 5
Removal and installation of cylinder head assembly .................................................................. 12
Removal and installation of engine hood assembly .................................................................... 25
Removal and installation of radiator ............................................................................................ 29
Removal and installation of air aftercooler .................................................................................. 32
Removal and installation of hydraulic oil cooler assembly .......................................................... 34
Removal and installation of engine assembly ............................................................................. 36
Removal and installation of engine front oil seal assembly......................................................... 43
Removal and installation of engine rear oil seal assembly ......................................................... 46
Removal and installation of cooling fan and fan motor assembly ............................................... 49
Removal and installation of fuel tank assembly .......................................................................... 52
Power train, Part 1 SEN03788-00
Disassembly and assembly of transfer assembly ....................................................................... 2
Removal and installation of parking brake assembly .................................................................. 21
Disassembly and assembly of parking brake assembly.............................................................. 23
Power train, Part 2 SEN03789-00
Removal and installation of front axle assembly ......................................................................... 2
Removal and installation of rear axle assembly .......................................................................... 4
Disassembly and assembly of axle housing assembly ............................................................... 7
Disassembly and assembly of differential assembly ................................................................... 15
Undercarriage and frame SEN03790-00
Removal and installation of center hinge pin .............................................................................. 2
Removal and installation of counterweight assembly ................................................................. 11
Hydraulic system SEN03791-00
Removal and installation of HST pump and 4-gear pump assembly .......................................... 2
Disassembly and assembly of HST pump assembly .................................................................. 6
Removal and installation of HST motor 1 assembly ................................................................... 33
Removal and installation of HST motor 2 assembly ................................................................... 35
Disassembly and assembly of HST motor assembly .................................................................. 37
Removal and installation of work equipment control valve assembly ......................................... 53
Removal and installation of hydraulic tank .................................................................................. 55
Disassembly and assembly of hydraulic cylinder assembly........................................................ 57
Work equipment SEN03792-00
Removal and installation of work equipment assembly .............................................................. 2
Cab and its attachments SEN03793-00
Removal and installation of operator's cab and floor frame assembly ........................................ 2
Removal and installation of operator's cab glass (Stuck glass) .................................................. 7
Removal and installation of air conditioner unit........................................................................... 15
Electrical system SEN03794-00
Removal and installation of monitor panel .................................................................................. 2
Removal and installation of engine controller assembly ............................................................. 4
Removal and installation of HST controller assembly ................................................................. 6
Removal and installation of KOMTRAX terminal assembly ........................................................ 7

90 Diagrams and drawings


Hydraulic diagrams and drawings SEN03093-00
Hydraulic circuit diagram............................................................................................................. 3
Electrical diagrams and drawings SEN03094-01
Electrical circuit diagram ............................................................................................................. 3
Connector arrangement diagram ................................................................................................ 23

WA200-6 11
SEN03090-02

WA200-6 Wheel loader


Form No. SEN03090-02

©2007 KOMATSU
All Rights Reserved
Printed in Japan 10-07 (01)

12
SEN03091-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

00 Index and foreword 1


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 ........................................................................................... 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

WA200-6 1
SEN03091-00 00 Index and foreword

Safety notice 1 (Rev. 2007/03)


Important 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.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.

1. General precautions 7) If welding repairs are needed, always


k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with Wearing protective goggles
7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc.
Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.

2 WA200-6
00 Index and foreword SEN03091-00

3) When disassembling or assembling, sup- 8) 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. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.

WA200-6 3
SEN03091-00 00 Index and foreword

4. Precautions for sling work and making


signs
1) 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. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.

4 WA200-6
00 Index and foreword SEN03091-00

q 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. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over
16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
warning lamp, and check safety. 25 55.3 5.6
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.

WA200-6 5
SEN03091-00 00 Index and foreword

8. Precautions for disconnecting and con-


necting hoses and tubes in air conditioner
circuit
1) Disconnection
k 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).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.

2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.

a Example of O-ring (Fitted to every joint of


hoses and tubes)

a For tightening torque, see the precautions for


installation in each section of "Disassembly
and assembly".

6 WA200-6
00 Index and foreword SEN03091-00

How to read the shop manual 1

q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.

1. Composition of shop manual


This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.

00. Index and foreword


This section explains the shop manuals list, table of contents, safety, and basic information.

01. Specification
This section explains the specifications of the machine.

10. Structure, function and maintenance standard


This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.

20. Standard value table


This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.

30. Testing and adjusting


This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.

40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.

50. Disassembly and assembly


This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.

90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2. 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.

WA200-6 7
SEN03091-00 00 Index and foreword

3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.

q Revised edition mark


When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)

q Revisions
Revised brochures are shown in the shop manual composition table.

4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-


a Caution
dards are necessary when performing work.

4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.

3
Tightening Places that require special attention for tightening torque during
torque assembly.

2 Coat Places to be coated with adhesives, etc. during assembly.

5
Oil, coolant Places where oil, etc. must be added, and capacity.

6
Drain Places where oil, etc. must be drained, and quantity to be drained.

5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.

8 WA200-6
00 Index and foreword SEN03091-00

Explanation of terms for maintenance standard 1


The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.

1. Standard size and tolerance


q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.

Example:
Standard size Tolerance
–0.022
120
–0.126

a The tolerance may be indicated in the text


and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)

q Usually, the size of a hole and the size of


the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0

WA200-6 9
SEN03091-00 00 Index and foreword

2. Standard clearance and standard value 5. Clearance limit


q The clearance made when new parts are q 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. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

4. Repair limit and allowable value


q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.

10 WA200-6
00 Index and foreword SEN03091-00

Handling of electric equipment and hydraulic component 1


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. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).

Points to remember when handling electric


equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.

2. Main failures occurring in wiring harness


1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.

2) Defective crimping or soldering of connec-


tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

WA200-6 11
SEN03091-00 00 Index and foreword

3) 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
may be broken.

4) High-pressure water entering connector


The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.

5) Oil or dirt stuck to connector


If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.

12 WA200-6
00 Index and foreword SEN03091-00

3. Removing, installing, and drying connec-


tors and wiring harnesses
1) Disconnecting connectors
1] 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. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.

2] When removing from clips


q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.

q When removing a connector from a


clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.

3] Action to take after removing connec-


tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.

WA200-6 13
SEN03091-00 00 Index and foreword

2) Connecting connectors
1] 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.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.

14 WA200-6
00 Index and foreword SEN03091-00

3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q 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).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

WA200-6 15
SEN03091-00 00 Index and foreword

4) 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. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

16 WA200-6
00 Index and foreword SEN03091-00

4. Handling controller
1) 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.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5. Points to remember when troubleshooting


electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.

WA200-6 17
SEN03091-00 00 Index and foreword

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.

1. Be careful of the operating environment.


Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2. Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.

3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

4. Do not let any dirt or dust get in during


refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

18 WA200-6
00 Index and foreword SEN03091-00

5. 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. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.

WA200-6 19
SEN03091-00 00 Index and foreword

Handling of connectors newly used for engines 1


a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 107 – 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 – 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)

Disconnect connector (1) according to the fol-


lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.

20 WA200-6
00 Index and foreword SEN03091-00

3. Push lock type


q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)

Disconnect connector (3) according to the fol-


lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.

q 114 engine

q 107, 114 engine


Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3) While pressing lock (D), pull out connector


(4) in the direction of the arrow.

q 107 engine

a If the lock is on the underside, use


flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

WA200-6 21
SEN03091-00 00 Index and foreword

q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)


4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.

Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)

2) Connect the connector according to the


following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.

Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

22 WA200-6
00 Index and foreword SEN03091-00

How to read electric wire code 1


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. The electric wire code is helpful in understanding the electric circuit diagram.

Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.

Indicates size of wire by nominal No.


Size (Nominal No.) is shown in Table 2.

Indicates type of wire by symbol.


Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)

1. Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene

WA200-6 23
SEN03091-00 00 Index and foreword

2. Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
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 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

“f” of nominal No. denotes flexible”.

24 WA200-6
00 Index and foreword SEN03091-00

3. Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.

4. Types of circuits and color codes

(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –

WA200-6 25
SEN03091-00 00 Index and foreword

Precautions when carrying out operation 1


[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.]

1. Precautions when carrying out removal work


q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234

2) Split flange type hoses and tubes


Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

26 WA200-6
00 Index and foreword SEN03091-00

2. Precautions when carrying out installation work


q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operation


1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
If any part is loosened or damaged, retighten or repair it.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
If any part is loosened or damaged, retighten or repair it.

WA200-6 27
SEN03091-00 00 Index and foreword

4) Checking muffler and exhaust pipe for damage and looseness


1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.

28 WA200-6
00 Index and foreword SEN03091-00

Method of disassembling and connecting push-pull type coupler 1


k 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.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1

1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.

2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.

WA200-6 29
SEN03091-00 00 Index and foreword

Type 2

1. Disconnection
1) 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)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)

2. Connection
q 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. 9)

30 WA200-6
00 Index and foreword SEN03091-00

Type 3

1. Disconnection
1) 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)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)

2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)

WA200-6 31
SEN03091-00 00 Index and foreword

Standard tightening torque table 1


1. 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. A.

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370

a The following table corresponds to the bolts in Fig. B.

Thread diameter of bolt Width across flats Tightening torque


mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2

a Fig. A a Fig. B

32 WA200-6
00 Index and foreword SEN03091-00

2. 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


mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5

3. Table of tightening torques for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.

Thread diameter Width across flats Tightening torque Nm {kgm}


Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}

4. Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.

Nominal Thread diameter Width across flats Tightening torque Nm {kgm}


No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}

WA200-6 33
SEN03091-00 00 Index and foreword

5. 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.
a Apply the following torque when the threads are coated (wet) with engine oil.

Tightening torque Nm {kgm} Taper seal Face seal


Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –

6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.

Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —

7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.

Thread size Tightening torque


mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

34 WA200-6
00 Index and foreword SEN03091-00

8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.

Thread size Tightening torque


inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92

WA200-6 35
SEN03091-00 00 Index and foreword

Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.

Example: Method of using the conversion table to convert from millimeters to inches

1. Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches (B)


1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

36 WA200-6
00 Index and foreword SEN03091-00

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

Liters to U.S. Gallons


1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

WA200-6 37
SEN03091-00 00 Index and foreword

Liters to U.K. Gallons


1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

38 WA200-6
00 Index and foreword SEN03091-00

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408

100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119

150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830

200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

WA200-6 39
SEN03091-00 00 Index and foreword

Temperature

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8


–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8


–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8


–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0


–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0


–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0


–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

40 WA200-6
00 Index and foreword SEN03091-00

WA200-6 41
SEN03091-00

WA200-6 Wheel loader


Form No. SEN03091-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

42
SEN03092-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

01 Specification 1

Specification and technical data


Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10

WA200-6 1
SEN03092-00 01 Specification

2 WA200-6
01 Specification SEN03092-00

Specification dimension drawing 1

Item Unit WA200-6


Machine weight (with BOC) kg 9,555
Normal load kN {kg} 31.4 {3,200}
Bucket capacity (heaped, with BOC) m3 2.0
Engine model — Komatsu SAA4D107E-1 Diesel engine
Engine rated output
•Net [ISO 9249/SAE J1349] (*1) kW{HP}/rpm 94 {126}/2,000
•Gross [SAE J1955] (*2) 95.2 {128}/2,000
A Overall length (with BOC) mm 6,985
B Overall height mm 3,110
C Overall height with bucket lifted up mm 4,885
D Overall width mm 2,375
E Minimum ground clearance mm 425
F Bucket width mm 2,550
G Dumping clearance Bucket tip/BOC tip mm 2,820/2,760
H Dumping reach Bucket tip/BOC tip mm 975/1,000
I Dumping angle degree 45
Min. turning radius Bucket tip/BOC tip mm 5,830/5,850
Center of outside tire mm 5,100
Permissible towing load kN {kg} 71.0 {7,250}
1st (forward/reverse) 4.0 – 13.0/4.0 – 13.0
2nd (forward/reverse) 13.0/13.0
Travel speed km/h
3rd (forward/reverse) 20.0/20.0
4th (forward/reverse) 34.5/34.5
*1: Indicates the value at the lowest cooling fan speed.
*2: Indicates the value of the engine alone (without cooling fan).
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
91 kW {122 HP}/2,000 rpm
a BOC: Abbreviation for Bolt-On Cutting edge

WA200-6 3
SEN03092-00 01 Specification

Specifications 1

Machine model name WA200-6


Serial No. 70001 and up
Machine weight kg 9,555
Machine weight (front wheel) in
Weight

kg 3,785
SAE travel posture
Machine weight (rear wheel) in
kg 5,770
SAE posture
Bucket capacity (heaped) m3 2.0
Normal load kN {kg} 31.4 {3,200}
Travel speed
• Forward 1st 4.0 – 13.0
• Forward 2nd 13.0
km/h
• Forward 3rd 20.0
• Forward 4th 34.5
• Reverse 1st 4.0 – 13.0
Performance

• Reverse 2nd 13.0


km/h
• Reverse 3rd 20.0
• Reverse 4th 34.5
Max. traction force
• Forward 86 {8,800}
kN{kg}
• Reverse 86 {8,800}
Gradeability deg. 25
Min. turning radius
mm 5,100
(center of outside tire)
Turning radius (cutting edge/BOC tip),
mm 5,830/5,850
SAE travel posture
Overall length (with BOC) mm 6,895
Overall width (chassis) mm 2,375
Bucket width (with BOC) mm 2,550
Overall height (cab top) mm 3,110
Overall height with bucket lifted up mm 4,885
Wheelbase mm 2,840
Tread mm 1,930
Minimum ground clearance mm 425
Dimension

Max. hinge pin height mm 3,685


Dumping clearance
mm 2,820/2,760
(cutting edge/BOC tip)
Dumping reach
mm 975/1,000
(cutting edge/BOC tip)
Steering angle deg. 38 (frame stopper 40)
Bucket tilt-back angle
deg. 48/67
(operating posture/Max. height)
Bucket tilt-forward angle
deg. 45
(max. height)
Digging depth, 10°
mm 285/320
(cutting edge/BOC tip)
a BOC: Abbreviation for Bolt-On Cutting edge

4 WA200-6
01 Specification SEN03092-00

Machine model name WA200-6


Serial No. 70001 and up
Model SAA4D107E-1
4-cycle, water-cooled, in-line 4-cylinder, direct injection type
Type
with turbocharger and air-cooled aftercooler
Cylinder bore x Cylinder stroke mm 107 x 124
Total piston displacement l {cc} 4.46 {4,460}
Rated output
• Net [ISO 9249/SAE J1349] (*1) 94 {126}/2,000
kW{HP}/rpm
• Gross [SAE J1995] (*2) 95.2 {128}/2,000
Engine

Performance

Max. torque (*1) Nm{kgm}/rpm 584 {59.6}/1,400


g/kWh
Min. fuel consumption 219 {161}
{g/HPh}
Max. speed at no load rpm 2,250
Min. speed at no load rpm 825
Starting motor 24 V, 4.5 kW
Alternator 24 V, 60 A
Battery (*3) 12 V, 88 Ah, 2 pieces
HST pump
• Type Variable displacement swash plate type piston pump
• Pump capacity cc/rev 0 – 90
HST motor 1
• Type Variable displacement bent axis type piston motor
• Pump capacity cc/rev 0 – 80
Power train

HST motor 2
• Type Variable displacement bent axis type piston motor
• Pump capacity cc/rev 46.5 – 80
Counter-shaft double acting planetary type, spur gear
Transfer
constant-mesh type, switching between 2 power trains
Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type, torque proportioning
Final drive Planetary gear single reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle

Front axle Fixed frame, semi-float type


Rear axle Center pin support type, semi-float type
Size 17.5–25–12PR
Rim size 25 x 13.00
Tire

Inflation pressure
• Front wheel kPa 294 {3.0}
• Rear wheel {kg/cm2} 294 {3.0}
*1:
Indicates the value at the lowest cooling fan speed.
*2:
Indicates the value of the engine alone (without cooling fan).
*3:
The battery capacity (Ah) is indicated in the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
91 kW {122 HP}/2,000 rpm

WA200-6 5
SEN03092-00 01 Specification

Machine model name WA200-6


Serial No. 70001 and up
Braking method 4-wheel brake, independent front and rear wheel brakes
Type of brake Enclosed wet multiple disc type
Main

Drive method Hydraulic drive


Operating method Foot-operated (with hydraulic booster)
Brake

Braking method Transmission output shaft brake


Parking

Type of brake Wet multiple disc type


Drive method Mechanical type
Operating method Manual lever type
Steering

Steering method Articulated chassis type

Drive method Hydraulic drive


Steering pump
• Type Gear type
• Delivery cm3/rev 50.1
Work equipment pump
Hydraulic pump

• Type Gear type


• Delivery cm /rev
3
32.0
Brake and cooling fan pump
• Type Gear type
• Delivery cm3/rev 12.4
Transfer lubrication pump
• Type Gear type
• Delivery cm /rev
3
12.4
Type Double-acting piston type
Cylinder bore mm 70
Steering cylinder
Hydraulic equipment

Piston rod outside diameter mm 40


Stroke mm 453
Max. distance between centers
mm 1,271
of pins
Min. distance between centers
mm 818
of pins
Type Double-acting piston type
Cylinder bore mm 120
Lift cylinder

Piston rod outside diameter mm 65


Cylinder

Stroke mm 673.5
Max. distance between centers
mm 1,817.5
of pins
Min. distance between centers
mm 1,144
of pins
Type Double-acting piston type
Cylinder bore mm 130
Bucket cylinder

Piston rod outside diameter mm 65


Stroke mm 493
Max. distance between centers
mm 1,447
of pins
Min. distance between centers
mm 954
of pins

6 WA200-6
01 Specification SEN03092-00

Machine model name WA200-6


Serial No. 70001 and up
Work equipment control valve
Control valve

• Type 2-spool type


• Set pressure MPa{kg/cm } 2
20.6 {210}
Steering valve
equipment
Hydraulic

• Type Orbit-roll type


• Set pressure MPa{kg/cm2} 20.6 {210}
Cooling fan motor
Motor

Fixed displacement, swash plate, piston type


• Type
<with reversible valve and flow control valve>
• Motor capacity cm3/rev 11.5
equipment

Type of link Single link


Work

Shape of bucket cutting edge Straight cutting edge with BOC

a BOC: Abbreviation for Bolt-On Cutting edge

WA200-6 7
SEN03092-00 01 Specification

Weight table 1

k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model name WA200-6
Serial No. 70001 and up
Engine (excluding coolant and oil) 470
Damper 3
Cooling assembly (excluding coolant and oil) 69
• Radiator 10
• Oil cooler 9
• Aftercooler 10
Transfer oil cooler 3
Cooling fan motor 13
HST pump 67
HST motor 1 34
HST motor 2 34
Transfer 214
Front drive shaft 15
Rear drive shaft 4
Front axle
• With torque proportioning differential 522
• With limited slip differential 526
Rear axle
• With torque proportioning differential 492
• With limited slip differential 496
Axle pivot (Rear axle) 79
Wheel [25 x 13.00 ] (1 piece) 77
Tire [17.5–25–12 PR] (1 piece) 132
Hydraulic tank (excluding hydraulic oil) 77
4-gear pump 21
Work equipment control valve 19
Work equipment PPC valve 3
Priority valve 6
Orbit-roll valve 7
Cushion valve 4
Charge valve 6
Brake valve 10
Steering cylinder assembly (1 piece) 20
Lift cylinder assembly (1 piece) 77
Bucket cylinder assembly 76
Front frame 750
Rear frame 670
Counterweight 1,175
Additional counterweight (1 piece) 151
Engine hood (including side panel) 177
Fuel tank (excluding fuel) 97

8 WA200-6
01 Specification SEN03092-00

Unit: kg
Machine model name WA200-6
Serial No. 70001 and up
Lift arm (including bushing) 540
Bucket link 23
Bell crank 140
Bucket (2.0 m3, including BOC) 785
Operator's cab
800
(including air conditioner and interior parts)
Operator seat 41
Air conditioner unit 5
Battery (1 piece) 33
a BOC: Abbreviation for Bolt-On Cutting edge

WA200-6 9
SEN03092-00 01 Specification

Table of fuel, coolant and lubricants 1

a For details of notes (Notes 1 and 2…) in the table, see "Operation and Maintenance Manual".

10 WA200-6
01 Specification SEN03092-00

Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 17 15.5
Transfer case 6.5 5.0
Hydraulic system 120 58
Axle (front/rear) 18 18
Cooling system 17 —
Fuel tank 177 —

WA200-6 11
SEN03092-00

WA200-6 Wheel loader


Form No. SEN03092-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

12
SEN03250-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Engine and cooling system


Engine mount and transfer mount................................................................................................................... 2
Damper ........................................................................................................................................................... 3
Cooling system ............................................................................................................................................... 4
Cooling system hydraulic piping diagram ....................................................................................................... 5
Cooling fan motor............................................................................................................................................ 7

WA200-6 1
SEN03250-00 10 Structure, function and maintenance standard

Engine mount and transfer mount 1

2 WA200-6
10 Structure, function and maintenance standard SEN03250-00

Damper 1

Unit: mm

No. Check item Criteria Remedy

Distance between HST pump Standard size Repair limit


1 installation surface and boss tip
Adjust
75.1 ±0.8
Wear on internal teeth of coupling
2 (resin)
Repair limit: 1.0 Replace

3. Coupling Outline
4. Boss q The damper protects the drive systems on and
5. HST pump input shaft after the engine from torsional vibrations by
6. Cover reducing the torsional vibrations of the engine
7. Flywheel due to the fluctuations in torque.
q The power from the engine is transmitted to
coupling (3) through flywheel (7), absorbing
torsional vibrations on coupling (3). Then it is
transmitted to HST pump through boss (4).

WA200-6 3
SEN03250-00 10 Structure, function and maintenance standard

Cooling system 1

1. Reservoir tank 5. Aftercooler


2. Oil cooler 6. Transfer oil cooler
3. Radiator cap 7. Cooling fan
4. Radiator 8. Cooling fan motor

Specifications
Radiator Oil cooler Aftercooler
Core type AL WAVE-4 CF40-1 AL WAVE
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
Total heat dissipation area
29.86 4.15 x 2 10.87
(m2)
Pressure valve cracking pressure 68.6
— —
(kPa {kg/cm2}) {0.7}
Vacuum valve cracking pressure 0 – 4.9
— —
(kPa {kg/cm2}) {0 – 0.05}

4 WA200-6
10 Structure, function and maintenance standard SEN03250-00

Cooling system hydraulic piping diagram 1

1. Cooling fan motor Outline


2. Strainer q Cooling fan motor (1) installed in the machine
3. Hydraulic tank rear side is driven by oil pressure from brake
4. Brake and cooling fan pump and cooling fan pump (4).
5. Charge valve

WA200-6 5
SEN03250-00 10 Structure, function and maintenance standard

6 WA200-6
10 Structure, function and maintenance standard SEN03250-00

Cooling fan motor 1

Type: LMF16

P: From pump through charge valve Specifications


T: To hydraulic tank through return filter Type: LMF16
TC: To hydraulic tank Capacity: 11.5 cm3/rev
Rated speed: 1,700 rpm
1. ER terminal Rated flow rate: 19.6 l/min
2. EF terminal Check valve cracking pressure:
3. Solenoid proportional pilot valve 0.013 MPa {0.13 kg/cm2}
4. ON/OFF pilot valve

WA200-6 7
SEN03250-00 10 Structure, function and maintenance standard

8 WA200-6
10 Structure, function and maintenance standard SEN03250-00

1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool

Unit: mm

No. Item Criteria Remedy


Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
18 Spool return spring diameter
length If damaged or
deformed, replace
58.8 N 47.1 N spring
44.84 x 12 33 —
{6 kg} {4.8 kg}
44.1 N 35.3 N
19 Spool return spring 35 x 8.5 34
{4.5 kg}

{3.6 kg}

WA200-6 9
SEN03250-00 10 Structure, function and maintenance standard

1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.

Principle of operation
q The pressurized oil from the hydraulic pump
flows through valve plate (7) into cylinder block
(5).
q This pressurized oil can flow on only to one
side of the (Y - Y) line connecting the top dead
center and bottom dead center of the stroke of
piston (4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (2 or 3 pistons).
q A single piston generates the force F1 [F1 (kg)
= P (kg/cm2) x xD2/4 (cm2)].
q This force works on thrust plate (2).
q Since thrust plate (2) is fixed to the specific
angle (a) to output shaft (1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y - Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.

10 WA200-6
10 Structure, function and maintenance standard SEN03250-00

2. Suction safety valve


1) Suction function (2) When the pump is stopped
q When the engine stops, the input revolution of
Function the pump becomes 0 rpm.
q If the fan pump stops, the pressurized oil does q The pressurized oil from the pump is not sup-
not flow into the motor. plied to port (P).
q Since the motor continues revolution because q As the pressurized oil is not supplied to (MA)
of the force of inertia, however, the pressure on side of the motor, the motor speed lowers
the outlet side of the motor rises. gradually to stop.
q When the pressurized oil stops flowing in from q If the motor shaft is revolved by the force of
inlet port (P), suction safety valve (1) sucks in inertia while the oil flow in port (P) is reducing,
the pressurized oil on the outlet side and sup- the oil in port (T) on the outlet side is sent by
plies it to port (MA) where there is not sufficient suction safety valve (1) to (MA) side to prevent
oil to prevent cavitation. cavitation.

Operation
(1) When pump is started
q The pressurized oil from the pump is supplied
to port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor,
the motor starts revolution.
q The pressurized oil on motor outlet (MB) side
of the motor returns through port (T) to the
tank.

WA200-6 11
SEN03250-00 10 Structure, function and maintenance standard

2) Safety function

Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Suction safety valve (1) is installed to protect
the fan system circuit.

Operation
q If the pressure in port (P) rises above the
cracking pressure of suction safety valve (1),
valve (2) of suction safety valve (1) opens to
release the pressurized oil into port (T).
q By this operation, generation of abnormally
high pressure in port (P) is prevented.

12 WA200-6
10 Structure, function and maintenance standard SEN03250-00

3. Operation of reversible valve


1) When the ON/OFF solenoid is 2) When the ON/OFF solenoid is energized
de-energized q When ON/OFF solenoid (1) is "energized",
q When ON/OFF solenoid (1) is "de-energized", valve (2) is switched.
the pressurized oil from the pump is shut off by q The pressurized oil from the pump flows to
valve (2). spool chamber (D) through port (C).
q Port (C) opens for the hydraulic tank circuit. q The pressurized oil in chamber (D) com-
q Spool (3) is pushed to the right by spring (4). presses spring (4).
q Port (MA) opens and pressurized oil flows in to q Spool (3) moves to the left.
revolve the motor in forward (clockwise). q Port (MB) opens and pressurized oil flows in to
rotate the motor in reverse (counterclockwise).

WA200-6 13
SEN03250-00 10 Structure, function and maintenance standard

4. Flow control valve


(continuously-variable type)
Function
This valve supplies the necessary pump delivery to
the motor, and returns the excessive oil to the
hydraulic tank.

q The motor speed increases in proportion to the


increase of the incoming oil (Q) as shown in
Fig 1.
q When the incoming flow rate is (Q1), motor
speed becomes (B) rpm.
q In order to reduce noise and loss of the motor,
this valve keeps the fan speed constant inde-
pendent of the flow rate to the motor.
q Even if the flow rate is increased from (Q0) to
(Q1), the valve maintains the motor speed con-
stant between points (A) and (C).

Operation
q For the flow control valve, the upstream pres-
sure of the orifice is conducted to the right side
of spool (1) and the downstream pressure of
the orifice is led to its left side.
q The differential pressure before and after ori-
fice (E) by the incoming flow rate to the motor
works on spring (2).
q In Fig. 1, when the flow rate (Q0) is increased
beyond, the differential pressure before and
after spool (1) becomes larger than the
installed load of spring (2).
q Spool (1) moves to the left and port (P) is con-
nected to port (T).
q The excessive oil in (Z) portion of Fig 1 flows to
the hydraulic tank through the flow control
valve, and the motor speed is kept constant
from (A) to (C).
q This flow control valve is a continuously-vari-
able type.
q As shown in Fig 2, it is possible to change the
flow control valve continuously while maintain-
ing the motor speed constant between (A') to
( C ') by c ha n g i n g t h e c o m m an d c u r r e n t
between the motor speed (A) and (C).

14 WA200-6
10 Structure, function and maintenance standard SEN03250-00

WA200-6 15
SEN03250-00

WA200-6 Wheel loader


Form No. SEN03250-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

16
SEN03251-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Power train
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

WA200-6 1
SEN03251-00 10 Structure, function and maintenance standard

2 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Power train 1

1. Engine
2. Damper
3. HST pump
4. 4-gear pump
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle

WA200-6 3
SEN03251-00 10 Structure, function and maintenance standard

Power train system diagram 1

4 WA200-6
10 Structure, function and maintenance standard SEN03251-00

1. Engine Outline
2. Damper q The power from engine (1) is transmitted to
3. HST pump HST pump (3) after its torsional vibrations have
4. Steering pump been reduced with damper (2) installed on the
5. Work equipment pump flywheel.
6. Brake and cooling fan pump q The power from engine (1) is also transmitted
7. Transfer lubrication pump to HST pump (3) and the HST charge pump
8. High-pressure hose being built in HST pump (3) as well as steering
9. HST motor 1 pump (4), work equipment pump (5), brake
10. HST motor 2 and cooling fan pump (6) and transfer lubrica-
11. Emergency steering valve (if equipped) tion pump (7) being connected to HST pump
12. Transfer (3).
13. Transfer clutch q The directional selector valve and servo piston
14. Parking brake installed on HST pump (3) continuously modify
15. Front drive shaft the oil discharge direction and discharged
16. Front axle amount responding to inclination of the swash
17. Differential plate.
18. Wet multiple disc type brake q HST motors (9) and (10) are installed on trans-
19. Final drive fer (12) and connected to HST pump (3)
20. Front tire through high-pressure hose (8).
21. Rear drive shaft q The hydraulic power from HST pump (3)
22. Rear axle changes the rotating direction and speed of
23. Differential HST m oto rs (9) and (1 0) to cont ro l th e
24. Wet multiple disc type brake machine forward and reverse travel and travel
25. Final drive speed.
26. Rear tire q The power from HST motor 1 (9) is transmitted
to the output shaft through transfer clutch (13)
in transfer (12).
The power from HST motor 2 (10) is transmit-
ted to the output shaft through the gear in
transfer (12).
q As the parking brake lever is operated, parking
brake (14) being contained in the rear side of
transfer (12) activates the wet multiple disc
type brake to stop the machine.
q The power to the front side is transmitted to
front axle (16) through front drive shaft (15).
The power to the rear side is transmitted to
rear axle (22) through rear drive shaft (21).
q Speed of the power transmitted to axles (16)
and (22) is reduced on the pinion gear of differ-
entials (17) and (23), then transmitted to the
sun gear through the sun gear shaft.
q Speed of the power transmitted to the sun gear
is reduced on the planetary mechanism of final
drives (19) and (25), then transmitted to tires
(20) and (26) through the axle shaft and wheel.

WA200-6 5
SEN03251-00 10 Structure, function and maintenance standard

Drive shaft 1

1. Front axle Outline


2. Front drive shaft q The power from the transfer output shaft is
3. Transfer transmitted to front axle (1) and rear axle (5)
4. Rear drive shaft through front drive shaft (2) and rear drive
5. Rear axle shaft (4).
q When the machine is articulated or when it
receives traveling impacts or working impacts,
the distances between the transfer and the
front and rear axles change. The drive shafts
absorb fluctuations in the angle and length with
the universal joints and slip joint so that the
power will be transmitted without damaging the
parts even when the machine is exposed to
above impacts or changes in the component
positions.

6 WA200-6
10 Structure, function and maintenance standard SEN03251-00

HST hydraulic piping diagram 1

1. Hydraulic tank
2. HST pump
3. HST drain oil filter
4. Clutch solenoid valve
5. HST oil filter
6. HST motor 1
7. HST motor 2

WA200-6 7
SEN03251-00 10 Structure, function and maintenance standard

HST pump 1

a HST: Abbreviation for HydroStatic Transmission

1. Directional selector solenoid valve Specifications


2. High-pressure cutoff valve
Model name A4VG90DA
3. Speed-related valve (DA valve)
4. Charge pump Variable displacement
Type swash plate type piston
5. Low-pressure relief valve pump
6. Servo cylinder Theoretical delivery
7. High-pressure relief valve 0 – 90
(cc/rev)
8. Control plate High-pressure relief valve
9. Cylinder block set pressure 44.1 {450}
10. Piston (MPa {kg/cm2})
11. Swash plate High-pressure cutoff valve Effective differential
set pressure pressure
(MPa {kg/cm2}) 41.2 {420}
Low-pressure relief valve
set pressure 2.45 {25}
(MPa {kg/cm2})

8 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Operation

Flow of power Flow of oil

q The HST pump is installed on the damper of q Inclination of swash plate (11) starts reciprocat-
the engine flywheel. ing movement of piston (10). The pumping
q The power from the engine is transmitted to action initiated by this reciprocating movement
the HST pump through the flywheel and suctions or discharges the oil in cylinder block
damper. (9) continuously.
q The HST pump is equipped with directional q The pumping action directs the oil flow in a cer-
selector solenoid valve (1) and servo cylinder tain definite direction so that it may flow to the
(6). HST motor.
q Driving the machine forward or reverse acti- q Reversing the inclination of swash plate (11)
vates directional selector solenoid valve (1), reverses the suction and discharge ports and,
tilting swash plate (11) and, as a result, caus- as a result, reversing the oil discharging direc-
ing the switch between the oil suction and dis- tion, too.
charge ports. q Piston (10) does not stroke when swash plate
q The HST pump is built-in cylinder block and 9 (11) is at neutral, thus the oil is not discharged.
pistons (10) rotate along with drive shaft (12). q Increasing or decreasing the inclination (angle)
q Tips of piston (10) slides on the swash plate of swash plate (11) changes the stroke of pis-
surface of swash plate (11) that does not ton (10), allowing to control the travel speed.
rotate. q If the amount of the oil in the low-pressure cir-
cuit (the oil to be returned from the motor to the
pump) becomes insufficient due to leakage of
oil in the HST pump, HST motor and control
valve, the charge pump supplies the oil
through speed-related valve (3) and the check
valve on high-pressure relief valve (7).

WA200-6 9
SEN03251-00 10 Structure, function and maintenance standard

High-pressure relief valve 1

1. Nut Function
2. Locknut q This valve is installed on the HST pump. If the
3. Poppet spring oil pressure on the high pressure circuit side
4. Check spring across the HST pump and HST motor goes
5. Main piston beyond the set pressure, it drains the pressure
6. Valve seat to the low pressure circuit side.
7. Pilot poppet This valve sets the maximum pressure of the
8. Adjustment screw HST circuit in this manner to protect the circuit.
q If low level of the oil is detected in the circuit,
the valve conducts oil from the HST charge
pump in order to protect cavitation.

10 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Operation

q Port (A) is connected to the high pressure cir- q As the oil pressure in chamber (B) goes lower,
cuit side of the HST pump, and ports (C) and the orifice of main piston (5) is activated and
(D) are connected to the low pressure circuit differential pressure is generated in port (A)
side of the pump. and chamber (B).
q Oil fills up chamber (B) after flowing through q The oil pressure in port (A) pushes main piston
the orifice of main piston (5). (5) in the left direction, relieving the abnormal
q Pilot poppet (7) is seated on valve seat (6). pressure generated in port (A) to port (C).
q If oil pressure in port (A) and chamber (B) goes q As the oil pressure in port (A) goes lower than
beyond the set pressure, pilot poppet (7) is that in port (C), check spring (4) pushes back
pushed in the left direction. As a result, the oil main piston (5) in the right direction.
pressure in chamber (B) is released to port (C) q The oil in port (C) is conducted to port (A)
through chamber (D) and the oil pressure in through chamber (D) so that the oil level in port
chamber (B) is decreased. (A) may not go low.
q Increasing or decreasing the repulsive force of
poppet spring (3) allows adjusting the set pres-
sure.
q When increasing the set pressure, remove the
nut to loosen the locknut and screw the adjust-
ment screw. When decreasing, loosen the
adjustment screw.

WA200-6 11
SEN03251-00 10 Structure, function and maintenance standard

Low-pressure relief valve 1 q When increasing the set pressure, loosen lock-
nut (1) and screw adjustment screw (2). When
decreasing, loosen the adjustment screw.

1. Locknut
2. Adjustment screw
3. Piston
4. Spring

Function
q This valve is installed on the HST pump. If the
oil pressure on the low pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil to the
hydraulic tank.
This valve sets the oil pressure of the HST
pump charge circuit in this manner to protect
the circuit.

Operation

q Port (A) is connected to the HST pump charge


circuit and port (B) is connected to the drain
circuit.
q As long as port (A) is below the set pressure,
oil does not flow to port (B).
q If oil pressure in port (A) goes beyond the set
pressure, piston (3) is pushed in the right direc-
tion. As a result, the oil pressure in port (A) is
released to port (B) and the oil pressure in port
(A) is decreased.
q Increasing or decreasing the repulsive force of
spring (4) allows adjusting the set pressure.

12 WA200-6
10 Structure, function and maintenance standard SEN03251-00

HST charge pump 1

1. Cover bolt Specifications


2. Pump gear Gear pump
Type
3. Key (inscription type)
4. Coupling Theoretical delivery
19.6
5. Drive shaft (cc/rev)
6. Plate
7. Charge pump cover
8. Crescent separator plate Function
q This pump is connected to the HST pump drive
Outline shaft (5) with coupling (4). Pumping action is
q This pump is installed on the HST pump. It, turned on as it is rotated.
working in conjunction with the HST pump, q It contains pump gear (2) and crescent separa-
supplies oil to the HST speed-related valve tor plate (8) to suction or delivery oil continu-
and the low-pressure relief valve on the HST ously in the direction shown in the figure.
pump.

WA200-6 13
SEN03251-00 10 Structure, function and maintenance standard

Speed-related valve (DA valve) 1

1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet

Function
q It diverges the oil from the HST charge pump
into 2 parts. One part flows to the directional
selector solenoid valve and other part flows to
the low-pressure relief valve.

Operation
q Port (A), port (D) and port (C) are connected to
the HST pump charge circuit, low-pressure
relief valve circuit and directional selector sole-
noid valve circuit, respectively.
q The oil from the HST charge pump constantly
flows to the low-pressure relief valve circuit
through port (A), orifice of pilot poppet (5),
chamber (B) and port (D).
q Orifice of pilot poppet (5) applies to the oil
pressure from the HST charge pump. As the
result, the differential pressure is generated in
port (A) and chamber (B).
q Oil pressure in port (A) pushes pilot poppet (5)
in the left direction to flow the oil in chamber
(B) to the directional selector solenoid valve
circuit through port (C).
q A set of pilot poppet (5) is consisted of poppet
spring (3) and spring seat (4).
q When decreasing the set pressure, loosen
locknut (1) and screw adjustment screw (2).
When increasing, loosen the adjustment
screw.

14 WA200-6
10 Structure, function and maintenance standard SEN03251-00

High-pressure cutoff valve 1

1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat

Function
q This valve is installed on the HST pump. If the
oil pressure on the high pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil in the
servo cylinder circuit to the hydraulic tank.
This valve sets the maximum pressure of the
HST pump circuit in this manner to protect the
circuit.

Operation
q Port (A), port (B), port (Pc) and port (T) are
connected to the high pressure circuit in the
reverse travel, high pressure circuit in the for-
ward travel, speed-related valve circuit and
drain circuit, respectively.
q As oil pressure in (A) side goes high, shuttle
spool (7) is pushed down and closes the port
(B) side circuit.
q Oil pressure on port (A) side pushes up piston
(5) and, at the same time, pushes up spool (4),
too, by compressing spring (3).
q Port (Pc) and port (T) are opened, releasing
abnormal pressure generated in port (Pc) to
port (T).
q As oil pressure in port (Pc) goes low, the
swash plate angle of the HST pump is
reduced. As a result, the pump delivery is
reduced and the HST pump circuit is pro-
tected.

WA200-6 15
SEN03251-00 10 Structure, function and maintenance standard

HST motor 1

a HST: Abbreviation for HydroStatic Transmission


HST motor 1

1. Drive shaft Specifications


2. Piston
Model name A6VM80EP
3. Cylinder block
4. Port plate Type Variable displacement bent
axis type piston motor
5. EP servo valve
Theoretical delivery
(cc/rev) 0 – 80
High-pressure relief valve
set pressure 44.1 {450}
(MPa {kg/cm2})
High-pressure cutoff Effective differential pressure
valve set pressure 41.2 {420}
(MPa {kg/cm2})
Low-pressure relief valve
set pressure 2.45 {25}
(MPa {kg/cm2})

16 WA200-6
10 Structure, function and maintenance standard SEN03251-00

HST motor 2

1. Drive shaft Specifications


2. Piston
Model name A6VM80HA
3. Cylinder block
4. Port plate Variable displacement bent
Type
axis type piston motor
5. HA servo valve
Theoretical delivery
6. Directional shuttle valve (cc/rev)
46.5 – 80
High-pressure relief valve
set pressure 44.1 {450}
(MPa {kg/cm2})
High-pressure cutoff
Effective differential pressure
valve set pressure
41.2 {420}
(MPa {kg/cm })2

Low-pressure relief valve


set pressure 2.45 {25}
(MPa {kg/cm2})

WA200-6 17
SEN03251-00 10 Structure, function and maintenance standard

Principle Operation
q It is assumed that the shaft of the disc is sup- q Pressurized oil from the HST pump flows to the
ported to enable free rotation of the disc. Force back side of piston (2) through the HST motor
F being applied aslant to the disc is divided inlet port, and is activated by inclination of pis-
into force F1 orthogonal to the disc and force ton (2) and cylinder block (3) as the rotating
F2 that works in the circumferential direction of force of drive shaft (1).
the disc. Force F1 pushes the disc in the axial q As the HST motor is rotated forward or
direction and force F2 rotates the disc clock- reverse, the oil in the high pressure circuit side
wise. is conducted to the directional shuttle valve (6).
q Also when force F' works on the disc instead of q As a large load is applied to the motor being
force F, it is likewise divided into force F1' and connected to servo valve (5), the pressure dif-
F2'. Force F2' rotates the disc counterclock- ference is generated between the high pres-
wise. sure circuit side and directional shuttle valve
(6), allowing the servo cylinder to increase
inclination of cylinder block (3).

Structure
q 7 pistons (2) are installed on the disc portion of
drive shaft (1) like spherical joints. They are
housed in cylinder block (3) having a certain
angle to drive shaft (1).
q As external load to the HST motor is
increased, servo valve (5) and directional shut-
tle valve (6) work to increase inclination of cyl-
inder block (3) and piston (2), reducing the
revolving speed and increasing the torque.

18 WA200-6
10 Structure, function and maintenance standard SEN03251-00

EP servo valve 1

1. Motor 1 solenoid valve Operation


2. EP servo valve q Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP
4. Servo cylinder servo valve (2).
q When the current value given to motor 1 sole-
Function noid valve (1) is small (when F1 < F2), EP
q This valve is installed on the rear side of HST servo valve (2) conducts the oil pressure on
motor 1. It controls the motor displacement the motor high pressure side circuit to the
depending on the current value given to motor small diameter side (S) of servo cylinder (4)
1 solenoid valve (1). and releases the oil pressure on the large
diameter side (L) to the tank (motor housing).
As the result, the servo cylinder (4) is moved
toward the min side.
q When the current value given to motor 1 sole-
noid valve (1) is large (when F1 > F2), EP
servo valve (2) conducts the oil pressure to the
large diameter side (L) to move servo cylinder
(4) toward the max side using the difference in
area between the large diameter and small
diameter side (S).
q Magnitude of spring (3) force varies depending
on the position of servo cylinder (4) (motor dis-
placement).
q The current value given to motor 1 solenoid
valve (1) controls the motor displacement to
the position where suction power F1 and
spring force F2 balance.

WA200-6 19
SEN03251-00 10 Structure, function and maintenance standard

HA servo valve 1

1. Motor 2 solenoid valve Operation


2. HA servo valve q If the load to the motor is small, HA servo valve
3. Servo cylinder (2) conducts oil pressure to the small diameter
side (S) through the directional shuttle valve
Function and releases the oil pressure on the large
q This valve is installed in the rear side of HST diameter side (L) to the tank (motor housing).
motor 2. In order to bring out the motor output Servo cylinder (3) moves toward the min side,
corresponding to the external load to the minimizing the motor displacement.
motor, it controls the motor displacement using q If a large load is applied to the motor during, for
the oil pressure of the circuit being selected instance, uphill travel, HA servo valve (2) is
from the directional shuttle valve. switched to conduct the oil pressure from the
directional shuttle valve to the large diameter
side (L). As a result, the difference in area
between the large diameter side (L) and small
diameter side (S) moves servo cylinder (3)
toward the max side. The motor displacement
becomes the maximum and generates large
torque.
q As motor 2 solenoid valve (1) is energized, HA
servo valve (2) conducts the oil pressure from
the directional shuttle valve to the large diame-
ter side (L) independent of the magnitude of
the load to the motor to set the motor displace-
ment to the maximum.

20 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Directional shuttle valve 1

1. Directional selector solenoid valve


2. Directional shuttle valve

Function
q This valve is installed in the rear side of HST
motor 2. It controls the destination of the oil
pressure to work on the HA servo valve refer-
encing the incoming signal, which corresponds
to the directional signal of the directional selec-
tor solenoid valve on the HST pump.
Above process reduces the decelerating
impacts that results when the oil pressure is
switched.

Operation
q Directional selector solenoid valve (1) inter-
locks with the directional selector valve on the
HST pump, since it has received the signal that
is corresponding to the directional signal to be
sent to the directional selector solenoid valve
on the HST pump.
q Directional shuttle valve (2) is activated by
directional selector solenoid valve (1) and con-
trols the destination of the oil pressure to work
on the HA servo valve.

WA200-6 21
SEN03251-00 10 Structure, function and maintenance standard

Transfer 1

a: Clutch port
b: Lubrication inlet port
c: Lubrication suction port

1. HST motor 2 mounting section


2. HST motor 1 mounting section
3. Oil filler pipe
4. Transfer
5. Parking brake lever
6. Speed sensor

22 WA200-6
10 Structure, function and maintenance standard SEN03251-00

1. HST motor 1
2. Input shaft
3. Transfer clutch
4. Carrier
5. Ring gear (number of teeth: 80)
6. Planetary pinion (number of teeth: 24)
7. Planetary shaft
8. Motor 1 gear (number of teeth: 44)
9. Sun gear (number of teeth: 28)
10. Parking brake
11. Rear coupling
12. Output gear (number of teeth: 58)
13. Spacer
14. Output shaft
15. Front coupling

WA200-6 23
SEN03251-00 10 Structure, function and maintenance standard

Input shaft

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between input shaft and size Shaft Hole clearance limit
1 bearing (front) +0.011 0 –0.023 –
50 —
–0.005 –0.012 0.005
Clearance between input shaft 0 +0.013 –0.006 –
2 bearing and cage (front)
80
–0.013 –0.006 0.026

Clearance between input shaft and +0.011 0 –0.023 –


3 bearing (middle)
50
–0.005 –0.012 0.005

Clearance between input shaft 0 +0.013 –0.006 –


4 bearing and ring gear (middle)
80
–0.013 –0.006 0.026

Clearance between input shaft and +0.011 0 –0.023 –


5 bearing (rear)
45
–0.005 –0.012 0.005

Replace
Clearance between input shaft 0 +0.013 –0.006 –
6 bearing and carrier (rear)
75
–0.013 –0.006 0.026

Clearance between press fitting +0.039 0 –0.054 –


7 shaft and bearing
55
+0.020 –0.015 –0.020

Clearance between press fitting 0 –0.016 –0.038 –


8 shaft bearing and motor 1 gear
100
–0.018 –0.038 0.002

Clearance between piston and –0.085 +0.040 0.085 –


9 spacer
177
–0.125 0 0.165

–0.550 +0.046 0.550 –


10 Clearance between piston and cage 222
–0.650 0 0.696

11 Clearance between clutch housing


and front case
200
+0.061
+0.015
+0.046
0
–0.061 –
0.031

24 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Thickness of separator plate
12 1.7 ±0.05 1.6

Strain on separator plate — 0.05 0.15

Thickness of friction plate 2.2 ±0.08 1.8


13
Strain on friction plate — 0.02 0.25

14 Load of wave spring


(height: 2.2 mm)
1,010 N
{103 kg}
±101 N
{±10.3 kg}
804 N
{82 kg}
Inside diameter of seal ring contact +0.021
25 25.1
surface 0
+0.15
Width of seal ring groove 2.5 2.7
+0.10
15
–0.01
Width of seal ring 2.5 2.3
–0.03

Thickness of seal ring 1.2 ±0.1 1.05 Replace

Inside diameter of seal ring contact +0.030


70 70.1
surface 0
+0.15
Width of seal ring groove 3 3.3
+0.10
16
–0.01
Width of seal ring 3 2.7
–0.03

Thickness of seal ring 2.9 ±0.1 2.75

Inside diameter of seal ring contact +0.022


120 120.5
surface 0
+0.1
Width of seal ring groove 4.5 5.0
0
17
0
Width of seal ring 4.36 3.9
–0.1

Thickness of seal ring 3 ±0.1 2.7

18 Backlash between sun gear and


planetary pinion
0.078 – 0.252

19 Backlash between planetary pinion


and ring gear
0.100 – 0.407

20 Backlash between motor 1 gear and


output gear
0.170 – 0.453

— Side clearance of planetary gear


(on both sides)
0.35 – 0.80

WA200-6 25
SEN03251-00 10 Structure, function and maintenance standard

Output shaft

26 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between output shaft size Shaft Hole clearance limit
1 and bearing (front) +0.030 0 –0.045 –
60 —
+0.011 –0.015 –0.011
Clearance between output shaft 0 –0.015 –0.040 –
2 bearing and cage (front)
110
–0.018 –0.040 0.003

Clearance between output shaft +0.030 0 –0.045 –


3 and bearing (rear)
65
+0.011 –0.015 –0.011

Clearance between output shaft 0 –0.015 –0.040 –


4 bearing and rear case (rear)
120
–0.018 –0.040 0.003

Clearance between oil seal and +0.170 +0.054 –0.170 –


5 cage (front)
100
+0.080 0 –0.026

Clearance between dust seal and +0.400 +0.054 –0.400 – Replace


6 cage (front)
100
+0.200 0 –0.146

Clearance between oil seal and +0.170 +0.054 –0.170 –


7 cage (rear)
100
+0.080 0 –0.026

Clearance between dust seal and +0.400 +0.054 –0.400 –


8 cage (rear)
100
+0.200 0 –0.146

Clearance between output shaft 0 +0.030 0–


9 and spacer
60
–0.030 0 0.060

Standard size Tolerance Repair limit


10 Inside diameter of coupling oil seal
contact surface (front) 0
75 74.8
–0.074

11 Inside diameter of coupling oil seal


contact surface (rear)
75
0
–0.074
74.8

Standard size Standard clearance Clearance limit


12 Clearance
case
between cage and front
0.7 0.1 – 1.3 —
Adjust with shims

13 Free
shaft
rotational torque of output
3.9 – 5.9 Nm {0.4 – 0.6 kgm}

WA200-6 27
SEN03251-00 10 Structure, function and maintenance standard

28 WA200-6
10 Structure, function and maintenance standard SEN03251-00

1. HST motor 2
2. Motor 2 gear (number of teeth: 44)
3. Strainer
4. Drain plug

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between input shaft and size Shaft Hole clearance limit
5 bearing +0.030 0 –0.045 –
55 —
+0.011 –0.015 –0.011
Replace
Clearance between input shaft 0 +0.022 –0.013 –
6 bearing and cage
90
–0.015 –0.013 0.037

Backlash between motor 2 gear and


7 output gear
0.170 – 0.453

WA200-6 29
SEN03251-00 10 Structure, function and maintenance standard

Outline Operation of clutch


q The transfer is equipped with 2 HST motors. It
selects a gear speed out of 1st - 4th speed Clutch is "engaged" (fixed)
both in the forward and reverse travels and
transmits it to the output shaft. It changes the
gear speed by varying output and revolving
direction of the HST motors and combinations
of the transfer clutches.

Relation between transfer clutch and transfer


clutch pressure at respective speed ranges
Speed
Transfer clutch Transfer clutch pressure
range
1st Engaged OFF
2nd Engaged OFF
Travel Travel Travel Travel
speed speed speed speed q As the oil from the clutch solenoid valve is cut
3rd 0 – A km/h A – 20 km/h 0 – A km/h A – 20 km/h off, piston (2) is pushed back in the right direc-
Engaged Disengaged OFF ON tion by the repulsive force of spring (1).
Travel Travel Travel Travel q Piston (2) compresses plates (3) and discs (4)
speed speed speed speed and the rotation of discs (4) is stopped by the
4th 0 – A km/h A – 34.5 km/h 0 – A km/h A – 34.5 km/h
frictional force.
Engaged Disengaged OFF ON q As the internal teeth of disc (4) are meshed
*1: The travel speeds listed above are the ones when the with the external teeth of ring gear (5), ring
tires of the size 17.5-25 are worn. And value A varies gear (5) is fixed.
depending on the opening ratio of the accelerator pedal.

Clutch is "disengaged" (released)


Relationship between accelerator pedal angle
and travel speed (A) for starting transfer clutch
switching modulation
Accelerator pedal angle (%)
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o 8 km/h 8 – 10 km/h 10 km/h
Disengaged (B)
Disengaged o
7 km/h 7 – 9 km/h 9 km/h
Engaged (C)

q The oil from the clutch solenoid valve is pres-


sure-fed to the back side of piston (2), and
pushes piston (2) in the left direction by com-
pressing spring (1).
q Plates (3) and discs (4) are released from the
frictional force, setting ring gear (5) to the neu-
tral position.
q Wave spring (6) is assembled between plates
(3) to accelerate return of piston (2) as the
clutches are released. And at the same time, it
helps smooth separation of plates (3) and
discs (4) in order to prevent drag turning.

30 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Power transmitting route


Low speed mode

Transfer clutch (1) is fixed to transmit power of both HST motor 1 (2) and HST motor 2 (3).

Power of HST motor 1 (2) Power of HST motor 2 (3)


O O
Input shaft (4) O
O O
Sun gear (5) O
O O
Planetary pinion (6) O
O O
Carrier (7) O
O O
Motor 1 gear (8) Motor 2 gear (9)
O O
Output gear (10) i i
O
Output shaft (11)

WA200-6 31
SEN03251-00 10 Structure, function and maintenance standard

High speed mode

Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone.

Power of HST motor 2 (3)


O
Motor 2 gear (9)
O
Output gear (10)
O
Output shaft (11)

32 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Clutch solenoid valve 1

P: From HST charge pump Operation


A: To transfer clutch q When the current value of input signal is large,
T: To drain the transfer clutch drains oil pressure.
q As the current value of input signal becomes
1. Clutch solenoid valve smaller, oil pressure of the transfer clutch goes
2. Plunger higher inversely proportional to the current
3. Coil value.
4. Push pin q If the current value of input signal is further
5. Spring lowered until the oil pressure of the transfer
6. Spool clutch reaches the oil pressure at which oil is
7. Body pressure-fed from the HST charge pump, the
oil pressure of the transfer clutch remains at
this level even if the current value may be fur-
ther decreased.

WA200-6 33
SEN03251-00 10 Structure, function and maintenance standard

Axle 1

Front axle 1

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Oil temperature sensor

34 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Rear axle 1

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder

WA200-6 35
SEN03251-00 10 Structure, function and maintenance standard

Differential 1

Front differential 1

1. Pinion (number of teeth: 9)


2. Shaft
3. Bevel gear (number of teeth: 43)
4. Sun gear shaft
5. Bevel pinion (number of teeth: 12)
6. Side gear (number of teeth: 12)

36 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Unit: mm
No. Check item Criteria Remedy

7 Starting torque of bevel gear 88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear) Adjust

Standard size Tolerance Repair limit


8 Thickness of pinion washer
3 ±0.08 2.8
Replace

9 Thickness of side gear washer 2 ±0.05 1.8

10 Thickness of shim in differential


side bearing carrier (one side)
0.50 – 1.35
Adjust
11 Backlash of bevel gear 0.20 – 0.33

12 End play of pinion


(or starting torque)
0 – 0.162
(0 – 61 N {0 – 6.2 kg} (at cage blot hole))
Replace

13 Thickness of shim in differential


housing and cage assembly
0.50 – 1.23 Adjust

Standard Tolerance Standard Clearance


size Shaft Hole clearance limit

14 Clearance of differential
side bearing Outer race 112.713
+0.025 –0.004 –0.054 –

0 –0.029 –0.004
+0.066 +0.013 –0.066 –
Inner race 69.85 —
+0.045 0 –0.032
0 –0.048 –0.088 –
Outer race 130 —
–0.018 –0.088 –0.030
15 Clearance of bearing on
pinion shaft gear side +0.039 0 –0.054 –
Inner race 60 —
+0.020 –0.015 –0.020
0 –0.041 –0.076 –
Clearance of bearing on Outer race 120
–0.015 –0.076 –0.026

16 pinion shaft coupling
side +0.039 0 –0.054 – Replace
Inner race 55 —
+0.020 –0.015 –0.020

17 Clearance
spider
between pinion gear and
28
–0.06
–0.11
+0.10
+0.05
0.11 –
0.21

Clearance in installation position of


–0.110 +0.081 0.110 –
18 differential housing piston 261
–0.191 0 0.272

(between housing and piston)
Clearance in installation position of
–0.100 +0.072 0.100 –
19 bearing carrier piston 241
–0.172 0 0.244

(between piston and carrier)
0 0 –0.035 –
Clearance between Outer race 110 —
–0.015 –0.035 0.015
20 drive shaft and cage
bearing +0.021 0 +0.002 –
Inner race 50 —
+0.002 –0.012 +0.033

WA200-6 37
SEN03251-00 10 Structure, function and maintenance standard

Rear differential 1

1. Pinion (number of teeth: 9)


2. Shaft
3. Bevel gear (number of teeth: 43)
4. Sun gear shaft
5. Bevel pinion (number of teeth: 12)
6. Side gear (number of teeth: 12)

38 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Unit: mm
No. Check item Criteria Remedy

7 Starting torque of bevel gear 88.2 – 205.8 Nm {0.9 – 2.1 kgm} (outside of bevel gear) Adjust

Standard size Tolerance Repair limit


8 Thickness of pinion washer
3 ±0.08 2.8
Replace

9 Thickness of side gear washer 2 ±0.05 1.8

10 Thickness of shim in differential


side bearing carrier (one side)
0.50 – 1.35
Adjust
11 Backlash of bevel gear 0.20 – 0.33

12 End play of pinion


(or starting torque)
0 – 0.162
(0 – 61 N {0 – 6.2 kg} (at cage blot hole))
Replace

13 Thickness of shim in differential


housing and cage assembly
0.50 – 1.23 Adjust

Standard Tolerance Standard Clearance


size Shaft Hole clearance limit

14 Clearance of differential
side bearing Outer race 112.713
0 –0.004 –0.029 –

–0.018 –0.029 0.014
+0.066 0 –0.081 –
Inner race 69.85 —
+0.045 –0.015 –0.045
0 –0.023 –0.063 –
Outer race 130 —
–0.018 –0.063 –0.005
15 Clearance of bearing on
pinion shaft gear side +0.039 0 –0.054 –
Inner race 60 —
+0.020 –0.015 –0.020
0 –0.041 –0.076 – Replace
Clearance of bearing on Outer race 120
–0.015 –0.076 –0.026

16 pinion shaft coupling
side +0.039 0 –0.054 –
Inner race 55 —
+0.020 –0.015 –0.020

17 Clearance
spider
between pinion gear and
25.18
–0.13
–0.18
+0.10
+0.05
0.180 –
0.280

Clearance in installation position of


–0.110 +0.081 0.110 –
18 differential housing piston 261
–0.191 0 0.272

(between housing and piston)
Clearance in installation position of
–0.100 +0.072 0.100 –
19 bearing carrier piston 241
–0.172 0 0.244

(between piston and carrier)

WA200-6 39
SEN03251-00 10 Structure, function and maintenance standard

Outline While machine is traveling straight

q The power from the engine is transmitted to


the front and rear axles through the torque
converter, transmission and drive shaft.
q In each axle, the direction of the power is q While the machine is traveling straight, the
changed by 90° and the speed is reduced by right and left wheels rotate at the same speed.
bevel pinion (1) and bevel gear (5). Then, the Accordingly, pinion (4) in the differential
power is transmitted through pinion (4) to sun assembly does not rotate and the power of car-
gear shafts (2). rier (6) is transmitted through pinion (4) and
q Speed of the power transmitted to the sun gear side gear (3) to right and left sun gear shafts
is further reduced by the final drive of the plan- (2) evenly.
etary gear type, and then transmitted to the
axle shafts and wheels. While machine is turning

q While the machine is turning, the right and left


wheels rotate at different speeds. Accordingly,
pinion (4) and side gear (3) in the differential
rotate and transmit the power of carrier (6) to
sun gear shafts (2), depending on the differ-
ence in rotation speed between the right and
left wheels.

40 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Torque proportioning differential 1

Outline Operation
Straight travel (When the road resistances
under both tires are the same)

q When the road resistances under the both tires


are the same, distance (a) from pinion (4) to
the meshing point of left side gear (7) and dis-
tance (b) to the meshing point of right side
gear (3) are the same.
q Accordingly, left traction force (TL) and right
traction force (TR) are balanced.

Travel on soft ground (When the road resis-


tances under both tires are different)

q A 4-wheel-drive wheel loader, as a construc-


tion machine, must naturally work on places
where the ground condition is bad. If its tires
slip in such places, its function lowers and the
lives of the tires are shortened. To solve this
problem, the torque proportioning differential is
used.
q Pinion (4) of this differential has an odd num-
ber of teeth. The meshing points of pinion (4)
and side gears (3) change according to the dif-
ference of the road resistance. Consequently,
the traction forces of the tires on both sides q When the tires slip on soft ground, the side
change. gear of the tire on the less road resistance side
turns forward. As a result, the meshing points
of pinion (4) and the side gears change.
q If left side gear (7) turns forward a little, dis-
tance (a) from the pinion to the meshing point
of the left side gear becomes longer than dis-
tance (b) to the meshing point of the right side
gear, and then (a) and (b) are balanced at a
point where (a) x (TL) = (b) x (TR). The ratio of
(a) : (b) changes up to 1 : 1.38, depending on
the meshing condition.

WA200-6 41
SEN03251-00 10 Structure, function and maintenance standard

q Accordingly, the pinion does not run idle and


the drive force is transmitted to both side gears
and the tires do not slip until the ratio of (a) : (b)
becomes 1 : 1.38, or the difference between
the road resistances under both tires becomes
38%.
q The lives of the tires are lengthened 20 - 30%
and the working capacity is increased by the
above effect.

42 WA200-6
10 Structure, function and maintenance standard SEN03251-00

WA200-6 43
SEN03251-00 10 Structure, function and maintenance standard

Limited slip differential 1

(if equipped)

1. Plate
2. Disc
3. Pinion (number of teeth: 12)
4. Washer
5. Side gear (number of teeth: 24)
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear (number of teeth: 43)
10. Case

44 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit

3
11 Thickness of plate
±0.02 2.9
3.1

+0.04
12 Thickness of disc 2.5
–0.03
2.45

13 Thicknesses of washer 2 ±0.05 1.8

14 Clearance between disc and plate


(total clearance on both sides)
0.2 – 0.6
Replace
15 End play of side gear in axial
direction (one side)
0.13 – 0.36

16 Backlash of case and plate 0 – 0.5

17 Backlash of side gear and disc 0.13 – 0.32

Standard Tolerance Standard Clearance


size Shaft Hole clearance limit
18 Clearance between spider and
differential pinion –0.110 +0.05 0.110 –
25.4 —
–0.160 0 0.210

WA200-6 45
SEN03251-00 10 Structure, function and maintenance standard

Operation of limited slip differential While machine is traveling straight


q The power from the transmission is transmitted When the drive forces of the right and left
through bevel gear (9), case (10), pressure wheels are balanced
ring (8), shaft (7), pinion (3) and side gear (5), [When the road conditions (coefficient of friction)
and then divided to the right and left shafts. under both wheels and the wheel loads are even,
q The brake unit consisting of disc (2) and plate and the center of load is at the center of the bucket]
(1) is installed to the back side of side gear (5).
It generates braking torque in proportion to the
torque transmitted from pressure ring (8) to
shaft (7).
q Since the brake torque restricts the rotation of
side gears (5) and case (10), right and left side
gears (5) cannot rotate freely. Thus, the opera-
tion of the differential is restricted.

Mechanism of generation of braking torque by


right and left side gears (5)

q Shaft (7) is supported on the cam surfaces


being provided on the surfaces of pressure
rings (8) that are facing each other.
q The power (= torque) transmitted from pres-
sure rings (8) to shaft (7) is transmitted on the q The power from the transmission is distributed
cam surfaces. Force (Fa) to separate pressure evenly by the differential gears to the right and
rings (8) from each other is generated by incli- left. Under this condition, the slip limits of the
nation of the cam surfaces in proportion to the right and left wheels are the same. Accord-
transmitted torque. ingly, even if the power from the transmission
q Separating load (Fa) acts on the brake on the may exceed the slip limits, both wheels slip
back side of each side gear (5) to generate and the differential does not work.
braking torque. No load is applied to the brake on the back
side of the side gear.

46 WA200-6
10 Structure, function and maintenance standard SEN03251-00

When the drive forces of the right and left Difference in wheel drive force by type of differen-
wheels are unbalanced tials when either wheel slipped
[When the road conditions (coefficient of friction) Wheel drive force
under both wheels and the wheel loads are uneven, (drive force of slipping wheel is 1)
and either wheel slips more easily] Slipping wheel Locked wheel Total (ratio)
Example 1. When either wheel is on soft ground
Limited slip
in digging work differential 1 2.64 3.64 (1.53)
Example 2. When either wheel is on snow and (if equipped)
the other one is on asphalt in snow Torque
removing work proportioning
1 1.38 2.38 (1)
Example 3. When the right and left wheel loads differential
are unbalanced in travel on a slope (standard)
Conventional
1 1 2 (0.84)
differential

Torque proportioning differential


q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.53 times of the torque propor-
tioning differential.
Conventional differential
(this is not applied with this machine.)
q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.82 times of the conventional dif-
ferential.

While machine is turning

q The power from the transmission is evenly


divided between the right and left by the differ-
ential gear. If, however, the divided drive force q The same gears as that for the conventional
exceeds the wheel slip limit of the slip side, differential are employed for the limited slip dif-
surplus of the driving force is transmitted to the ferential. Thus, they allow to smoothly gener-
opposite side (lock side) brake through the ate a difference in rotation speed between the
brake and case on the gear back side. Then outer and inner wheels that is necessary for
the power is distributed to the lock side wheel. tuning.
q The differential starts working only as the sur-
plus portion of the drive force has exceeded
the braking force.

WA200-6 47
SEN03251-00 10 Structure, function and maintenance standard

Final drive 1

Front final drive 1

1. Planetary gear (number of teeth: 26)


2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)

48 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Rear final drive 1

1. Planetary gear (number of teeth: 26)


2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)

WA200-6 49
SEN03251-00 10 Structure, function and maintenance standard

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between planetary gear size Shaft Hole clearance limit
6 bearing and shaft +0.025 +0.013 –0.025 – Replace
33.338 —
+0.013 0 0
Clearance between axle housing +0.100 +0.100 –0.100 –
7 and ring gear
276
+0.030 0 +0.070

Clearance between oil seal and


8 housing
Max. 0.2 Adjust

+0.400 +0.063 –0.400 –


Housing 140 —
Press fitting part of axle +0.200 0 –0.137
9 shaft seal 0 –0.200 –0.400 –
Shaft 105 —
–0.054 –0.400 –0.146
0 –0.028 –0.068 –
Clearance of press Outer race 130 —
–0.025 –0.068 –0.003
10 fitting part of axle Replace
housing bearing +0.045 0 –0.065 –
Inner race 85 —
+0.023 –0.020 –0.023
0 –0.028 –0.068 –
Clearance of press Outer race 125 —
–0.018 –0.068 –0.010
11 fitting part of axle
housing bearing +0.030 0 –0.045 –
Inner race 80 —
+0.011 –0.015 –0.011

12 End play of axle shaft 0 – 0.1 Adjust

+0.025 +0.207 0.120 –


13 Clearance of guide pin 12
+0.007 +0.145 0.200
— Replace

a Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and
assembly.

50 WA200-6
10 Structure, function and maintenance standard SEN03251-00

Outline

a The figure shows the front axle.


q The final drive finally reduces speed of the
power from the engine to increase the drive
force.
q Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
q Speed of the power being transmitted from the
differential through sun gear shaft (5) is
reduced by the planetary gear unit to increase
the drive force.
The increased drive force is transmitted
through planetary carrier (2) and axle shaft (3)
to the tire.

WA200-6 51
SEN03251-00

WA200-6 Wheel loader


Form No. SEN03251-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

52
SEN03252-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Steering system
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

WA200-6 1
SEN03252-00 10 Structure, function and maintenance standard

2 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Steering piping diagram 1

1. Steering cylinder (right)


2. Orbit-roll valve
3. Hydraulic tank
4. Priority valve
5. Steering pump
6. 2-way restrictor valve
7. Cushion valve
8. Steering cylinder (left)

WA200-6 3
SEN03252-00 10 Structure, function and maintenance standard

Steering column 1

1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Tilt lever

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between steering shaft size Shaft Hole clearance limit
5 and column bushing
Replace
0 +0.15 0.05 –
19 0.4
–0.08 +0.05 0.23

4 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Priority valve 1

P: From steering pump LS: From Orbit-roll valve


CF: To Orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve

1. Relief valve body 7. Plug


2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed Installed
Free length Free length Installed load
12 Control spring length load
187 N 187 ± 14.7 N Replace
63.4 47.6 63.4 ± 1
{19.1 kg} {19.1 ± 1.5 kg}
132 N 132 ± 14.7 N
13 Relief spring 31 27.3
{13.3 kg}

{13.3 ± 1.5 kg}

WA200-6 5
SEN03252-00 10 Structure, function and maintenance standard

Outline Operation
q The priority valve is installed between the
steering pump and Orbit-roll valve and work When steering wheel is at "neutral" position
equipment control valve. It diverges the oil
from the steering pump to the steering circuit
or work equipment circuit. It is also used for
controlling the oil pressure from the priority
valve to the Orbit-roll valve in order to protect
the circuit.
Set pressure: 18.6 MPa {190 kg/cm2}

q When the engine is stopped, spool (3) is


pushed in the left direction by the repulsive
force of spring (4). Thus, port (M) and port (N)
are fully opened and port (M) and port (Q) are
closed.
q Starting the engine starts the steering pump
rotation, and the oil from the pump flows to port
(A) of the Orbit-roll valve through port (M) and
port (N).
q The oil that flew to chamber (P) through orifice
(m) of spool (3) pushes spool (3) in the right
direction by compressing spring (4).
q Port (M) and port (Q) are opened and port (M)
and port (N) are almost closed to stabilize
spool (3).
q Most of the oil from the pump flows to the work
equipment circuit through port (Q).

6 WA200-6
10 Structure, function and maintenance standard SEN03252-00

When steering wheel is "turned left" When steering cylinder is at stroke end

q Turning the steering wheel left changes the q Trying to continuously turn the steering wheel
angle between the sleeve and spool on the after the steering cylinder has reached the
Orbit-roll valve, switching flow of the oil. (see stroke end increases oil pressure in port (S).
"Orbit-roll valve".) q As the oil pressure in port (S) goes beyond the
q Part of the oil from the pump that has flown to set pressure of relief valve (10), the relief valve
port (A) is then conducted to the R.H. steering (10) releases the oil pressure in port (S) to the
cylinder through port (B) and Gerotor, and the hydraulic tank through port (T).
remaining portion of the oil flows to chamber q It generates differential pressure before and
(R) through orifice (b) and port (J). after orifice (r), breaking down the balance
q Change in the angle between the sleeve and between the difference pressure up to port (A)
spool on the Orbit-roll valve generates a differ- and after port (B) and the repulsive force of
ence pressure between the oil pressure up to spring (4). As a result, oil pressure up to port
port (A) and that after port (B). (A) becomes relatively higher.
q Spool (3) stabilizes at a position where the dif- q As port (A) oil pressure is increased, oil in
ference pressure between that of up to port (A) chamber (P) pushes spool (3) in the right direc-
and after port (B) [chamber (P) pressure - tion by compressing spring (4).
chamber (R) pressure] is balanced with the q Port (M) and port (N) are almost closed, and
repulsive force of spring (4). port (M) and port (N) are nearly fully opened to
q The ratio of diversion is determined by the dis- stabilize spool (3).
placement in angle between the spool and
sleeve on the Orbit-roll valve, namely the
opening ratio of port (A) and port (B). And
changing the operating distance of the steering
wheel enables its stepless adjustment.

WA200-6 7
SEN03252-00 10 Structure, function and maintenance standard

Orbit-roll valve 1

P: From steering pump LS: To priority valve


L: To steering cylinder T: To hydraulic tank
R: To steering cylinder

1. Gland
2. Valve body
3. Check valve
4. Gerotor
5. Spacer
6. Cover
7. Spacer
8. Drive shaft
9. Sleeve
10. Spool
11. Center pin
12. Centering spring
13. Anti-cavitation valve
14. Overload relief valve

8 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Outline Structure

q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the steering pump to the right or left nected to sleeve (8) through center pin (7)
steering cylinder to decide the travel direction (which is not in contact with spool (9) while the
of the machine. steering wheel is at "neutral") and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) that have rotary type q Top (B) of drive shaft (3) is engaged with cen-
direction selecting function and Gerotor (5) ter pin (7) and united with sleeve (8) and the
(combination of rotor (5a) and stator (5b)) that bottom is engaged with the spline of rotor (5a)
operates as a hydraulic motor during the nor- of the Gerotor (5).
mal steering operation and as a hand pump q 4 ports are provided on valve body (4). Each
(the steering wheel's operating effort becomes port is respectively connected to the pump cir-
too high to operate it actually) when the oil is cuit, tank circuit, L.H. steering circuit and R.H.
not supplied because of a trouble of the steer- steering circuit. And the ports of the pump side
ing pump or engine. and tank side are connected by the check
valve in the body. If the pump or engine fails,
the oil can be sucked through this check valve
directly from the tank side.

WA200-6 9
SEN03252-00 10 Structure, function and maintenance standard

Operation
When steering wheel is at "neutral" position

10 WA200-6
10 Structure, function and maintenance standard SEN03252-00

q When the steering wheel is at "neutral" posi-


tion, centering spring (2) sets center pin (7) to
the center of the oblong hole on spool (9) and
move of spool (9) and sleeve (8) is stopped.
q Port (A) from sleeve (8) pump, port (E) to the
Gerotor, port (F) to the R.H. steering circuit and
port (G) to the L.H. steering circuit cut off the
vertical grooves (B), (C) and (D) on spool (9).
q Orifice (b) of port (J) to the priority valve is con-
nected to vertical groove (B) on spool (9).
q Port (K) of sleeve (8) is connected to vertical
groove (M) and port (L) on spool (9).
q Due to connection and disconnection of the
ports and vertical grooves, the oil in the priority
valve being set to the pilot pressure is con-
ducted through port (J), orifice (b), vertical
groove (M) and port (K), then drained from port
(L) to the hydraulic tank.

WA200-6 11
SEN03252-00 10 Structure, function and maintenance standard

When steering wheel is "turned left"

12 WA200-6
10 Structure, function and maintenance standard SEN03252-00

q As the steering wheel is "turned left", spool (9) When steering wheel is at "stop" position
being connected to the drive shaft of the steer- q As operation of the steering wheel is stopped,
ing column is rotated counterclockwise. angular displacement between spool (9) and
q Since spool (9) and sleeve (8) are connected sleeve (8) disappears and the steering wheel
by centering spring(2), spool (9) compresses is returned to the neutral position by the repul-
centering spring (2). sive force of centering spring (2).
q An angular displacement corresponding to the
amount of compression of centering spring (2)
is generated between spool (9) and sleeve (8).
q Port (A) and vertical groove (B) are connected
first being followed by the connection between
vertical groove (B) and port (E), port (E) and
vertical groove (C), and vertical groove (C) and
port (G) to the L.H. steering circuit.
q Although the connection between vertical
groove (B) and orifice (b) of port (J) to the pri-
ority valve is maintained, port (K) of sleeve (8)
starts gradually closing vertical groove (M) and
port (L).
q Port (F) of the R.H. steering circuit is con-
nected to vertical groove (D) at the same time
as port (A) and vertical groove (B) are con-
nected.
q Due to connection and disconnection of the
ports and vertical grooves, the oil from the
pump flows from port (A) to vertical groove (B)
then flows to port (E), starting rotation of the
Gerotor. The oil discharged from the Gerotor
flows to the L.H. steering cylinder head side
through port (E), vertical groove (C) and port
(G).
q Oil pressure of vertical groove (M) is transmit-
ted to port (J) through orifice (b), then supplied
from port (J) as the pilot pressure of the priority
valve.
q The oil from the R.H. steering cylinder head is
drained to the hydraulic tank through port (F),
vertical groove (D) and port (H).

WA200-6 13
SEN03252-00 10 Structure, function and maintenance standard

Connection of hand pump and sleeve

q Above figure shows the suction and discharge q The internal gear of the Gerotor advances by 1
ports (P) of the Gerotor and connections with tooth with every 1/7 turn of the steering wheel
the sleeve ports. and discharges the oil from the pump accord-
q If the steering wheel is turned to the right, ports ing to the steering angle of the steering wheel.
(a), (c), (e), (g), (i), and (k) will be connected to Accordingly, the discharge amount varies in
the pump side by the vertical grooves of the proportion to the steering angle of the steering
spool. Likewise, ports (b), (d), (f), (h), (j), and (l) wheel.
are connected to the R.H. steering cylinder
head side.
Under the condition in Fig. 1, ports (1), (2) and
(3) are in the discharge state of the Gerotor
and connected to ports (l), (b), and (d) and the
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil form the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90° continued for
above condition. Under this state, ports (2), (3),
and (4) are in the suction state and connected
to ports (k), (a), and (c). Ports (5), (6), and (7)
are in the discharge state and connected to
ports (d), (f), and (h).
q As shown above, the ports in the discharge
state of the Gerotor are connected to the ports
being connected to the steering cylinder. The
ports in the suction state are connected to the
pump circuit.

14 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Role of centering spring

q Centering spring (2) is composed of 4 X-


shaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is generated between spool (9)
and sleeve (8).
As a result, the ports of spool (9) and sleeve
(8) are connected and the oil is sent to the
steering cylinder. When the steering wheel
stops turning, the Gerotor also stops turning.
Then, the oil is not sent to the steering cylinder
any more and its pressure rises.
To prevent this, when the steering wheel
stopped turning, Gerotor is turned by the reac-
tion force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) to
return the steering wheel to the "neutral" posi-
tion.

WA200-6 15
SEN03252-00 10 Structure, function and maintenance standard

2-way restrictor valve 1

1. Tube
2. Poppet
3. Body

Function
q In order to buffer the impacts resulting from the
momentum of the machine when switching the
steering, an orifice installed in the circuit near
to the cylinder controls the move of the cylinder
piston by giving pressure to the return oil.

Operation

q When flowing in the left direction (in the cylin- q When flowing in the right direction (to the cylin-
der's forward move direction), the oil pushes der's return direction), the oil conducted
open poppet (3), and flows from orifice (a) and through orifice (a) of poppet (3) alone, thus the
notch (b) of poppet (3). flow rate is restricted.

16 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Cushion valve 1

A: From steering cylinder left turning port Outline


B: From steering cylinder right turning port q If sudden increase or bouncing occurs in oil
pressure of the steering cylinder circuit, this
1. Valve seat valve mitigates the impacts by releasing the
2. Valve body highly pressurized oil to instantly to other line.
3. Spring
4. Poppet Function
5. Orifice q As highly pressurized oil rushed into port (A), it
6. Plug compresses spring (3) and opens poppet (4) of
7. Spring port (A) side, then flows through the center
8. Spool groove of spool (8) up to port (B) opening pop-
9. Plug pet (11) of port (B) side.
10. Spring q At the same time, the highly pressurized oil
11. Poppet flows to the pressure chamber of plug (6)
through orifice (5) of port (A) side. Then over-
coming the port (B) side pressure and repul-
sive force of spring (7), it pushes spool (8) in
the right direction, cutting off the flow of oil from
port (A) to port (B).
q Temporary flow of oil to the cushion valve
works as cushioning effects in mitigating the
steering impacts. After the operation of the
cushion valve is completed, the steering func-
tions as usual.
q If the pressure change on the steering cylinder
circuit is gradual, spool (8) cuts off the circuit
before poppet (4) opens. Thus, the cushion
valve remains inactivated.

WA200-6 17
SEN03252-00 10 Structure, function and maintenance standard

Steering cylinder 1

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing in size clearance limit
Shaft Hole
1 cylinder rod frame connecting part
and mounting pin 0 +0.180 0.042 –
40 —
–0.025 +0.042 0.205
Clearance between bushing in
0 +0.180 0.042 –
2 cylinder bottom frame connecting 40
–0.025 +0.042 0.205

Replace
part and mounting pin
Width of boss Width of hinge Standard (a + b) clearance
Connecting part of steering cylinder
3 and front frame Max. 0.5
50 53
(after shim is adjusted)
Connecting part of steering cylinder Max. 0.5
4 and rear frame
50 53
(after shim is adjusted)

18 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between piston rod and size Shaft Hole clearance limit
1 bushing –0.025 +0.132 0.031 –
40 0.496
–0.064 +0.006 0.196 Replace pin and
Clearance between piston rod 0 +0.180 0.042 – bushing
2 supporting shaft and bushing
40
–0.025 +0.042 0.205
1.0

Clearance between cylinder bottom 0 +0.180 0.042 –


3 supporting shaft and bushing
40
–0.025 +0.042 0.205
1.0

WA200-6 19
SEN03252-00 10 Structure, function and maintenance standard

Emergency steering piping diagram 1

(if equipped)

1. Steering pump
2. Priority valve
3. Orbit-roll valve
4. Check valve
5. Emergency steering valve
6. HST motor 2
7. Pressure switch (for detecting emergency steering operation)
8. Steering relief valve
9. Pressure switch (for detecting low oil pressure on steering)

20 WA200-6
10 Structure, function and maintenance standard SEN03252-00

Emergency steering valve 1

(if equipped)

PP: From steering pump 1. Check valve body


A: To HST motor 2 port A 2. Check valve
B: To HST motor 2 port B 3. Valve body
Y: To Orbit-roll valve 4. Pressure reducing valve
S: From hydraulic tank 5. Selector valve
G: To pressure switch

WA200-6 21
SEN03252-00 10 Structure, function and maintenance standard

Operation

When engine and steering pump are normal

q As long as the engine and steering pump are


operating normally, the oil being pressure-fed
from the steering pump flows to the Orbit-roll
valve, enabling the steering.
q The oil from the steering pump flows to port
(PP), pushes spool (1) in the left direction, then
cuts off the circuit from the HST motor to the
Orbit-roll valve.

22 WA200-6
10 Structure, function and maintenance standard SEN03252-00

When engine or steering pump is abnormal

q If, during travel, the steering pump fails to sup-


ply sufficient amount of oil to the Orbit-roll
valve due to a trouble on the engine or steering
pump, discharge pressure of the steering
pump goes low. As a result, spool (1) is
pushed back in the right direction by the repul-
sive force of spring (2).
q The high pressure side is selected for the oil
from the HST pump at check valves (3) and
(4), and the oil pressure is decreased to an
appropriate level at pressure reducing valve
(5).
q De-pressurized oil flows through port (Y) to the
Orbit-roll valve, enabling the steering.
q If the oil in the HST circuit goes low because of
flowing out to the steering circuit, oil is supplied
to the HST circuit by check valves (6) and (7).

a Thanks to the function of check valves (3) and


(4), the emergency steering system is operable
both in the forward and reverse travel.

WA200-6 23
SEN03252-00 10 Structure, function and maintenance standard

Steering relief valve 1

(if equipped)

P1: From steering pump Outline


P2: From emergency steering pump q The steering relief valve is installed to the right
T: Drain side of the transmission and used to hold the
S1: Steering pump oil pressure switch (Low) steering oil pressure to the set pressure.
S2: Steering pump oil pressure switch (Hi) Set pressure: 1.96 MPa {20 kg/cm2}
S3: Emergency steering oil pressure switch (cracking pressure at 0.5 l/min)

1. Block
2. Relief valve
3. Orifice

24 WA200-6
10 Structure, function and maintenance standard SEN03252-00

WA200-6 25
SEN03252-00

WA200-6 Wheel loader


Form No. SEN03252-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

26
SEN03253-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Brake system
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

WA200-6 1
SEN03253-00 10 Structure, function and maintenance standard

2 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Brake piping diagram 1

1. Hydraulic tank 8. Strainer


2. Brake valve 9. Slack adjuster (for front left side)
3. Brake and cooling fan pump 10. Front brake
4. Rear brake 11. Slack adjuster (for front right side)
5. Accumulator (for front side) 12. Slack adjuster (for rear right side)
6. Accumulator (for rear side) 13. Slack adjuster (for rear left side)
7. Charge valve

WA200-6 3
SEN03253-00 10 Structure, function and maintenance standard

Charge valve 1

4 WA200-6
10 Structure, function and maintenance standard SEN03253-00

P: From brake and cooling fan pump


T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (rear side)
ACC2: To accumulator (front side)
S: Brake operation sensor port
G: Gauge port

1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Unload valve
6. Relief valve

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between inverse shuttle size Shaft Hole clearance limit
7 valve and body –0.006 +0.011 0.006 –
12 0.029
–0.014 0 0.025
Clearance between plunger and –0.005 +0.009 0.005 –
8 body
8
–0.012 0 0.021
0.024

Clearance between unload valve –0.006 +0.011 0.006 –


9 and body
18
–0.017 0 0.028
0.032

Standard size Repair limit


Installed Installed Installed
Free length Free length Replace
10 Inverse shuttle valve return spring length load load
9.8 N 8.3 N
21.6 18.3 —
{1.0 kg} {0.85 kg}

11 Unload
(inside)
relief valve return spring
35.9 30.0
188 N
{19.2 kg}

160 N
{16.3 kg}

12 Unload relief valve return spring


(outside)
39.8 27.5
137 N
{14.0 kg}

116 N
{11.8 kg}
49 N 42 N
13 Unload valve return spring 51.6 45.0
{5.0 kg}

{4.3 kg}
4.9 N 4.2 N
14 Check valve return spring 11.5 9.0
{0.5 kg}

{0.43 kg}

Function
q The charge valve maintains the oil pressure
from the pump to the set pressure and accu-
mulates it in the accumulator.
q If the oil pressure from the pump goes beyond
the relief valve s et pres sur e, this valve
releases the oil pressure to the drain circuit in
order to reduce the load to the pump.

WA200-6 5
SEN03253-00 10 Structure, function and maintenance standard

Operation
When oil is not supplied to accumulator When oil is supplied to accumulator
(cut-out state) 1. Cut-in state

q Plunger (1) is moved in the left direction by the q As the accumulator pressure goes low, pres-
accumulator pressure, and maintains unload sure on port (E) goes low, allowing plunger (1)
relief valve (2) being pushed open. to move in the right direction and unload relief
q The oil in the spring chamber of unload valve valve (2) to close the drain circuit.
(3) is drained to the hydraulic tank through port q Since the oil pressure in port (F) and the spring
(F), unload relief valve (2) and port (T). chamber of unload valve (3) increases, unload
q Since oil pressure in port (F) is decreased, valve (3) moves in the right direction.
unload valve (3) moves in the left direction q Port (C) and port (B) are opened, conducting
being subjected to the action of the oil from the oil from the pump to port (B).
chamber (B). q As oil pressure in port (B) increases beyond
q Port (C) and port (D) are opened, supplying the set pressure of check valve (4), check
most of the oil from the pump to the cooling fan valve opens, allowing the oil to be supplied to
motor through port (P), ports (C) and (D), and the accumulator through port (E). The pressure
port (A). for supplying oil to the accumulator depends
on the set pressure of check valve (4).
q Amount of oil supplied to the accumulator is
constant independent of the engine speed,
thus surplus of the oil flows to the cooling fan
motor through port (A).
q Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.

6 WA200-6
10 Structure, function and maintenance standard SEN03253-00

When the oil pressure from the pump went


2. When pressure reaches cut-out pressure beyond the set pressure

q As pressure in port (F) reaches the set pres- q As oil pressure in chamber (B) reaches the set
sure (cut-out pressure of unload relief valve pressure of relief valve (6), relief valve (6) is
(2)), oil in the spring chamber of unload valve opened to drain the oil from the pump to the
(3) is drained to the hydraulic tank through port hydraulic tank through port (T).
(F), unload relief valve (2) and port (T). Above process protects the brake circuit by
q Plunger (1) is moved in the left direction by the restricting its maximum pressure.
accumulator pressure, and maintains unload
relief valve (2) being pushed open.
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the left direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).

WA200-6 7
SEN03253-00 10 Structure, function and maintenance standard

Brake valve 1

P1: From HST pump A: To Rear brake


T1: To hydraulic tank PB: From accumulator (front side)
T2: To steering pump (suction side) B: To front brake
PA: From accumulator (rear side)

1. Rod 5. Brake valve body (for rear)


2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between inching valve size Shaft Hole clearance limit
8 spool and body –0.022 +0.033 0.020 –
22.4 0.096
–0.053 0 0.086
Clearance between inching valve –0.022 +0.033 0.020 –
9 guide and body
22.4
–0.053 0 0.086
0.096

10 Clearance between inching valve


spool and guide
12
–0.050
–0.093
+0.050
0
0.050 –
0.143
0.157

Standard size Repair limit


Installed Installed Installed Replace
Free length Free length
11 Inching valve control spring length load load
24.5 N 20.8 N
34.7 16.7 —
{2.5 kg} {2.1 kg}
113 N 96 N
12 Brake valve control spring 35.6 24.0
{11.5 kg}

{9.8 kg}
19.6 N 16.7 N
13 Inching valve return spring 50.0 49.5
{2.0 kg}

{1.7 kg}
147 N 125 N
14 Brake valve return spring 114.9 52.4
{15.0 kg}

{12.7 kg}

8 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q The brake valve contains the inching valve to
regulate the control pressure of the HST pump.

Operation
When the brake pedal is pressed down

q Brake pedal (1) pressing effort is transmitted to When brake of one side is operated
spool (5) through rod (2), spool (3) and spring (when the other brake failed)
(4). q Even when only one side of the brakes
q As spool (5) is pushed in the right direction, remains operable due to, for instance, oil leak
port (Ta) is closed and the oil from the pump on the front or rear brake system, brake pedal
activates the rear brake after being conducted (1) pressing effort moves in the right direction
through the accumulator, port (PA), port (A) after being transmitted mechanically through
and rear brake piston. spool (5) and spool (6).
q As spool (5) is pushed in the right direction, q Oil from the pump is conducted normally to the
spool (6) is also pushed in the right direction, brake piston of the healthy system to enable
closing port (Tb). The oil from the pump flows stopping the machine as needed in order to
through the accumulator, port (PB) and port (B) ensure safety.
to the front brake piston to activate the front
brake.

WA200-6 9
SEN03253-00 10 Structure, function and maintenance standard

Balancing operation

q As the rear brake piston is filled with oil and the


oil pressure rises between port (PA) and port
(A), the oil being conducted to chamber (E)
through orifice (c) of spool (5) pushes spool (5)
in the left direction resisting repulsive force of
spring (4). As the result, port (PA) and port (A)
are disconnected.
q Since port (Ta) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q At the same time as spool (5) is moved to the
left, the front brake piston is filled up with oil,
increasing the oil pressure between port (PB)
and port (B). Thus, the oil conducted to cham-
ber (F) through orifice (d) of spool (6) pushes
back spool (6) in the left direction by the move
distance of spool (5). As the result, port (PB)
and port (B) are disconnected.
q Since port (Tb) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q The oil pressure of the rear brake circuit [port
(A) side] is balanced with the brake pedal
pressing effort, and the oil pressure of the front
brake circuit [port (B) side] is balanced with the
oil pressure of the rear brake circuit [port (A)
side].
q As spools (5) and (6) are moved in the right
direction to the stroke end, port (PA) and port
(A) as well as port (PB) and port (B) are fully
connected. As a result, oil pressure of the rear
brake cir cuit and the front br ake circuit
becomes equal to that from the pump.
q Braking force is adjustable by adjusting the
brake pedal pressing effort until spools (5) and
(6) are driven in the right direction to the stroke
end.

10 WA200-6
10 Structure, function and maintenance standard SEN03253-00

When brake pedal is released

q Releasing brake pedal (1) releases the pedal


pressing effort being applied to spool (5).
q Spool (5) is pushed back in the left direction by
the back pressure of the rear brake piston and
repulsive force of spring (7), and port (PA) and
port (A) are closed.
q At the same time, oil in the rear brake piston is
drained to the hydraulic tank through port (A)
and port (Ta), releasing the rear brake.
q At the same time as spool (5) is moved in the
left direction, spool (6) is also pushed back in
the left direction by the back pressure of the
front brake piston and repulsive force of spring
(7). As the result, port (PB) and port (B) are
closed.
q Oil in the front brake piston is drained to the
hydraulic tank through port (B) and port (Tb),
releasing the front brake.

WA200-6 11
SEN03253-00 10 Structure, function and maintenance standard

Inching valve 1

P1: From HST pump port Y Outline


T2: To steering pump (suction side) q The inching valve, which is contained in brake
valve (2), reduces the control oil pressure of
1. Brake pedal the HST circuit responding to stroke (S) of
2. Brake valve spool (3) in order to reduce the capacity of the
3. Spool HST pump.
4. Body

12 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Accumulator (for brake) 1

1. Cylinder
2. Free piston

Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (1) and free piston (2) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.

Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charge pressure 3.5 ± 0.1 {35.7 ± 1}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
10 {102}
(MPa {kg/cm2})

WA200-6 13
SEN03253-00 10 Structure, function and maintenance standard

Slack adjuster 1

A: From brake valve


B: To brake piston

1. Body
2. Check valve
3. Piston

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between piston and size Shaft Hole clearance limit
4 body –0.065 +0.052 0.065 –
30 0.163
–0.098 0 0.150
Clearance between check valve –0.013 +0.015 0.013 –
5 and body
10
–0.028 0 0.043
0.048

Standard size Repair limit Replace


Installed Installed Installed
Free length Free length
6 Piston return spring length load load
11.8 N 9.8 N
87.5 48.2 —
{1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25
{5.5 kg}

{4.7 kg}

14 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Function
q The slack adjuster is installed between the
brake valve and brake piston. It maintains the
time lag up to activation of the brake constant.

Operation
When brake is applied When brake is released

q The oil from the brake valve flows to port (A) q The oil being stopped between piston (1) and
and moves piston (1) in the right direction to brake piston pushes back piston (1) in the left
activate the brake using the oil being amassed direction, allowing the oil, equivalent in the vol-
between piston (1) and the brake piston. ume to piston (1) move distance, to return to
q The slack adjuster maintains the time lag up to the brake valve through port (A) then is drained
activation of the brake constant by operating to the hydraulic tank.
t he b r a k e u s i n g th e o i l b e i ng a m a s s e d
between piston (1) and the brake piston.
q If the oil between piston (1) and brake piston
goes low due to wear on the brake disc and
like, it pushes open check valve (2) to make up
the deficit.

WA200-6 15
SEN03253-00 10 Structure, function and maintenance standard

Brake 1

Front brake 1

1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)

16 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Unit: mm

No. Check item Criteria Remedy


Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5

Thickness of brake disc 6.5 ±0.15 5.7

11 Depth of lining groove 0.8 (min.) — 0.4

Thickness of lining 1.0 0.8 (min.) — Replace


Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring 19.0 ±0.1 18.7

Standard size Repair limit

13 Load of spring
(when 2 pieces are piled)
Installed height Installed load Installed load

6.5 2,253 N 1,800 N


{230 kg} {184 kg}

Outline
q The front brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).

WA200-6 17
SEN03253-00 10 Structure, function and maintenance standard

Rear brake 1

1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)

18 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5

Thickness of brake disc 6.5 ±0.15 5.7

11 Depth of lining groove 0.8 (min.) — 0.4

Thickness of lining 1.0 0.8 (min.) —


Replace
Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring
19.0 ±0.1 18.7

Standard size Repair limit

13 Load of spring
(when 2 pieces are piled)
Installed height Installed load Installed load
2,253 N 1,800 N
6.5
{230 kg} {184 kg}

Outline
q The rear brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).

WA200-6 19
SEN03253-00 10 Structure, function and maintenance standard

Operation
When brake is operated

q As the brake pedal is pressed, oil pressure (P)


being supplied through the hydraulic tank,
pump and brake charge valve to the brake cyl-
inder acts on piston (2) in the brake cylinder to
move the piston.
Accordingly, disc (4) between piston (2), inner
ring (3), and outer ring (5) is stopped and the
brake is applied to the machine.

When brake is released

q If the oil pressure is released, piston (2) is


returned to the original position by the return-
ing force of spring (8) and clearance is made
between inner ring (3) and outer ring (5), and
disc (4) becomes free.
The linings stuck to disc (4) have cross
grooves on them. While disc (4) is rotating, oil
flows in those grooves to cool the linings.

20 WA200-6
10 Structure, function and maintenance standard SEN03253-00

Parking brake control 1

1. Parking brake lever 4. Control cable


2. Parking brake lever bottom switch 5. Transfer
3. Parking brake lever intermediate switch 6. Multi-disc brake lever

Outline
q The parking brake is built in transfer (5). On
this mechanical parking brake, operating the
multi-disc brake lever (6) from parking brake
lever (1) allows "applying" or "releasing" the
parking brake.
q Pulling parking brake lever (1) on the opera-
tor's seat pulls up the multi-disc brake lever
(6), which is connected with control cable (4),
"applying" the parking brake.
q Returning parking brake lever (1) to its original
position pushes down the multi-disc brake
lever (6), which is connected with control cable
(4), "releasing" the parking brake.
q As long as the parking brake is "applied", cur-
rent to the directional solenoid valve on the
HST pump is cut off and the swash plate of the
HST pump is maintained at the neutral posi-
tion.

WA200-6 21
SEN03253-00 10 Structure, function and maintenance standard

Parking brake 1

1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
Thickness of plate
2.6 ±0.06 2.5
9
Strain on plate — 0.05 0.1
Replace
Thickness of brake disc 2.2 ±0.08 2.05
10
Strain on brake disc — 0.02 0.25

11 Load of wave spring


(height: 2.2 mm)
1,010 N
{103 kg}
±101 N
{±10.3 kg}
858 N
{87.6 kg}

Outline
q This parking brake is a wet multiple disc type
brake being operated mechanically to apply
braking to output shaft (8).
q Lever (1) is connected to the control cable. Ball
(3) provided between piston (4) and housing
(2), that are connected to lever (1), moves on
the slope of the piston groove responding to
the pulling distance of the parking brake lever.
By this move of the ball, piston (4) compresses
plate (5) and disc (6) to each other, thereby
applying brake to output shaft (8).

22 WA200-6
10 Structure, function and maintenance standard SEN03253-00

WA200-6 23
SEN03253-00

WA200-6 Wheel loader


Form No. SEN03253-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

24
SEN03254-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Undercarriage and frame


Axle mount and center hinge pin .................................................................................................................... 2

WA200-6 1
SEN03254-00 10 Structure, function and maintenance standard

Axle mount and center hinge pin 1

2 WA200-6
10 Structure, function and maintenance standard SEN03254-00

1. Front axle Outline


2. Tension bolt q Front axle (1) receives the force during work
3. Rear axle directly. Thus, it is fixed directly to front fame
4. Frame lock bar (5) with tension bolt (2).
5. Front frame q Rear axle (3) is designed to sway at the center
6. Center hinge pin of rear frame (7) so that each tire may contact
7. Rear frame the ground surface even when the machine is
8. Additional counterweight (if equipped) traveling on soft ground.
9. Counterweight q Front frame (5) and rear frame (7) are coupled
by the center hinge pin (6) with the bearing
between them. The right and left steering cylin-
ders connect the front frame (5) and rear frame
(7). They adjust the bending angle or the turn-
ing radius of the frame according to move of
the cylinder.

WA200-6 3
SEN03254-00 10 Structure, function and maintenance standard

4 WA200-6
10 Structure, function and maintenance standard SEN03254-00

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper hinge pin size Shaft Hole clearance limit
1 and rear frame (Small) –0.038 +0.100 0.038 –
50 —
–0.068 0 0.168
Clearance between upper hinge pin –0.038 +0.25 0.038 –
2 and spacer
50
–0.068 0 0.318

Clearance between upper hinge pin –0.038 0 0.026 –


3 and bearing
50
–0.068 –0.012 0.068

Clearance between upper hinge pin –0.073 0.023 –


4 and rear frame (Large)
66
–0.103
±0.05
0.153

Clearance between front frame and –0.08 –0.02 –0.04 –


5 spacer
105
–0.68 –0.12 0.66

Clearance between front frame and 0 –0.02 –0.120 –


6 upper hinge bearing
105
–0.015 –0.12 –0.005

Replace
Clearance of press fitting part of +0.07 –0.05 –0.220 –
7 upper hinge pin seal
89
–0.02 –0.15 –0.030

Clearance between lower hinge pin –0.20 +0.083 0.077 –


8 and rear frame bushing
70
–0.21 +0.123 0.127

Clearance between lower hinge pin –0.20 –0.097 0.078 –


9 and bearing
70
–0.21 –0.122 0.113

10 Clearance between front frame and


lower hinge bearing
89
–0.1
–0.12
–0.05
–0.15
–0.05 –
0.07

11 Clearance
bushing
between rear frame and
80
+0.084
+0.059
+0.054
0
–0.084 –
–0.005

Standard size Tolerance Repair limit


12 Height of upper hinge spacer
23 ±0.1 —

13 Standard thickness of shim


between upper hinge and retainer
1.3

14 Standard thickness of shim


between upper hinge and retainer
0.8
Adjust
3.92 – 5.88 Nm {0.4 – 0.6 kgm} (when shim is adjusted)
15 Tightening torque of upper hinge
retainer mounting bolt
59 – 74 Nm {6.0 – 7.5 kgm} (final value)

WA200-6 5
SEN03254-00 10 Structure, function and maintenance standard

Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thickness of thrust plate 0
10 —
–0.15
+0.3
2 Thickness of thrust washer 5
–0.1

Standard Tolerance Standard Clearance Replace


Clearance between shaft and hole size Shaft Hole clearance limit
3 on front support side –0.043 +0.550 0.093 –
170 —
–0.106 +0.050 0.656
Clearance between shaft and hole –0.043 +0.550 0.093 –
4 on rear support side
170
–0.106 +0.050 0.656

Standard thickness of shim in thrust


5 cap
0.2 —

6 WA200-6
10 Structure, function and maintenance standard SEN03254-00

WA200-6 7
SEN03254-00

WA200-6 Wheel loader


Form No. SEN03254-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

8
SEN03255-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Hydraulic system
Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control lever linkage ............................................................................................................. 4
Hydraulic tank ................................................................................................................................................. 6
4-gear pump.................................................................................................................................................... 8
Work equipment control valve........................................................................................................................11
PPC valve ..................................................................................................................................................... 27
Lock valve ..................................................................................................................................................... 36
Accumulator (for PPC circuit)........................................................................................................................ 37
ECSS valve................................................................................................................................................... 38
Accumulator (for ECSS)................................................................................................................................ 40

WA200-6 1
SEN03255-00 10 Structure, function and maintenance standard

Work equipment hydraulic piping diagram 1

2 WA200-6
10 Structure, function and maintenance standard SEN03255-00

1. Work equipment control valve Outline


2. Bucket cylinder q The hydraulic system is consisted of the HST,
3. Hydraulic tank steering, work equipment, brake, cooling fan
4. Work equipment PPC valve and transfer lubrication circuit. The work equip-
5. Lock valve ment circuit controls move of the lift arm and
6. Oil cooler bucket.
7. Check valve q The oil in hydraulic tank (3) is supplied to work
8. 4-gear pump equipment control valve (1) by work equipment
• Steering pump pump of 4-gear pump (8). When each spool of
• Work equipment pump the lift arm and bucket of work equipment con-
• Brake and cooling fan pump trol valve (1) is at the Hold position, the oil
• Transfer lubrication pump flows the drain circuit of work equipment con-
9. Accumulator (for ECSS) (if equipped) trol valve (1), is filtered on the return filter on
10. Lift cylinder hydraulic tank (3), then is returned to hydraulic
11. ECSS valve (if equipped) tank (3).
12. Accumulator (for PPC circuit) q Operating the work equipment control lever
operates the lift arm spool or bucket spool of
work equipment PPC valve (4).
The oil from work equipment PPC valve (4)
operates respective spools of work equipment
valve (1) with its oil pressure, then sends the
oil pressure to lift cylinder (10) or bucket cylin-
der (2) to operate the lift arm or bucket.
q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (1). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q Accumulator (for PPC circuit) (12) is installed
on the PPC pilot circuit so that the work equip-
ment can be lowered to the ground even while
the engine is stopped.
q Hydraulic tank (3) is pressurized, enclosed,
and equipped with the breather having the
relief valve, which doubles the oil filler cap
function. The breather applies pressure to the
tank and, at the same time, prevents genera-
tion of negative pressure in the tank to prevent
cavitation in the pump.

WA200-6 3
SEN03255-00 10 Structure, function and maintenance standard

Work equipment control lever linkage 1

Mono-lever type

1. Work equipment control lever


2. Wrist rest
3. Lock valve
4. Work equipment lock lever
5. Work equipment PPC valve
6. Wrist rest height adjustment lever

4 WA200-6
10 Structure, function and maintenance standard SEN03255-00

WA200-6 5
SEN03255-00 10 Structure, function and maintenance standard

Hydraulic tank 1

1. Oil filler cap and breather Specifications


2. Return filter Capacity of hydraulic tank (l) 83
3. Hydraulic tank
Quantity of oil in hydraulic tank (l) 58
4. Drain plug
5. Sight gauge Set pressure of bypass valve 0.2
6. Return filter bypass valve (MPa {kg/cm2}) {2.04}
7. Check valve Cracking pressure of check valve 0.1 ± 0.02
(MPa {kg/cm2}) {0.98 ± 0.2}

6 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Breather 1

1. Oil filler cap


2. Case
3. Lock-resetting knob
4. Sleeve
5. Poppet
6. Filter element

Prevention of negative pressure in tank


q Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated.
At this time, sleeve (4) is opened by the differ-
ential pressure between the tank pressure and
the atmospheric pressure to prevent genera-
tion of the negative pressure.
(set pressure of air intake valve:
3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2})

Prevention of pressure rise in tank


q While the hydraulic circuit is in operation, the
oil level in the tank rises as the hydraulic cylin-
ders operate, and the temperature rises. Con-
sequently, the pressure in the tank rises, too.
If the pressure in the tank rises beyond the set
level, poppet (5) is activated to release the
pressure in the tank to prevent rise of pressure
in the tank.
(set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})

WA200-6 7
SEN03255-00 10 Structure, function and maintenance standard

4-gear pump 1

(steering, work equipment, brake, cooling fan and transfer lubrication)

SAR (2)50 + 32 + SB (1)12 + 12

1. Steering pump Outline


2. Work equipment pump q The 4-gear pump is installed on the HST
3. Brake and cooling fan pump pump. The axial rotation drives this gear to
4. Transfer lubrication pump supply pressurized oil to the steering, work
equipment, brake, cooling fan and transfer.

8 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Unit: mm
No. Check item Criteria Remedy
Type Standard clearance Clearance limit
SAR(2)50
5 Side clearance SAR(2)32
0.10 – 0.15 0.19
SBR(1)12
SBR(1)12
SAR(2)50 0.06 – 0.125
Clearance between inside diameter SAR(2)32 0.06 – 0.125
6 of plain bearing and outside 0.20
Replace
diameter of gear shaft SBR(1)12
0.068 – 0.115
SBR(1)12
Type Standard size Allowance Repair limit
SAR(2)50 12
0
SAR(2)32 12
7 Pin driven depth –0.5
SBR(1)12 10 —
+0.5
SBR(1)12 7
0

8 Torque of spline rotating shaft 9.8 – 23.5 Nm {1.0 – 2.4 kgm}

Discharge Standard Allowable


Speed
Type pressure delivery delivery
(rpm)
(MPa {kg/cm2}) (l/min) (l/min)
Delivery —
— Oil: SAE10WCD SAR(2)50 138 127
Oil temperature: 45 – 55°C SAR(2)32 20.6 {210} 88 81
3,000
SBR(1)12 32 30
SBR(1)12 2.9 {30} 32 30

WA200-6 9
SEN03255-00 10 Structure, function and maintenance standard

10 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Work equipment control valve 1

2-spool type

A1: To bucket cylinder head PA1: From work equipment PPC valve
A2: To lift arm cylinder head PA2: From work equipment PPC valve
B1: To bucket cylinder bottom PB1: From work equipment PPC valve
B2: To lift arm cylinder bottom PB2: From work equipment PPC valve
P: From pump T: To hydraulic tank

WA200-6 11
SEN03255-00 10 Structure, function and maintenance standard

12 WA200-6
10 Structure, function and maintenance standard SEN03255-00

1. Main relief valve


2. Bucket spool
3. Lift arm spool
4. Suction safety valve
5. Check valve
6. Suction valve

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
7 Spool return spring
diameter
length

92.2 N 73.7 N
42.53 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
55.9 N 44.7 N
8 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}

{4.56 kg}
deformed, replace
spring
111 N 88.7 N
9 Spool return spring 53.35 x 12 38.5
{11.3 kg}

{9.04 kg}
72.6 N 58.1 N
10 Spool return spring 42 x 27.5 41
{7.4 kg}

{5.92 kg}
29.4 N 23.5 N
11 Check valve spring 39.5 x 11.2 25
{3 kg}

{2.4 kg}

WA200-6 13
SEN03255-00 10 Structure, function and maintenance standard

14 WA200-6
10 Structure, function and maintenance standard SEN03255-00

3-spool type

A1: To service actuator PA1: To service PPC valve


A2: To bucket cylinder head PA2: To work equipment PPC valve
A3: To lift arm cylinder head PA3: To work equipment PPC valve
B1: To service actuator PB1: To service PPC valve
B2: To bucket cylinder bottom PB2: To work equipment PPC valve
B3: To lift arm cylinder bottom PB3: To work equipment PPC valve
P: From pump T: To hydraulic tank

WA200-6 15
SEN03255-00 10 Structure, function and maintenance standard

16 WA200-6
10 Structure, function and maintenance standard SEN03255-00

1. Main relief valve


2. Service spool
3. Bucket spool
4. Lift arm spool
5. Suction safety valve
6. Check valve
7. Suction valve

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
8 Spool return spring
diameter
length

92.2 N 73.7 N
42.53 x 27.5 41 —
{9.4 kg} {7.52 kg}
If damaged or
55.9 N 44.7 N
9 Spool return spring 58.87 x 26.3 57.3
{5.7 kg}

{4.56 kg}
deformed, replace
spring
111 N 88.7 N
10 Spool return spring 53.35 x 12 38.5
{11.3 kg}

{9.04 kg}
72.6 N 58.1 N
11 Spool return spring 42 x 27.5 41
{7.4 kg}

{5.92 kg}
29.4 N 23.5 N
12 Check valve spring 39.5 x 11.2 25
{3 kg}

{2.4 kg}

WA200-6 17
SEN03255-00 10 Structure, function and maintenance standard

Relief valve
q As the pressurized oil in ports (A) and (B)
reaches the set pressure of spring (4), pilot
poppet (3) opens, leading the pressurized oil in
port (B) to port (C) through port (D), and pres-
sure in port (B) is decreased.

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
q As the pressure in port (B) goes low, the orifice
Function of main valve (1) generates differential pres-
q This valve is installed in the inlet of the work sure between ports (A) and (B). As a result, the
equipment control valve. When the oil pressure main valve is pushed open, and pressurized oil
increases beyond the specified level, it drains in port (A) flows to the drain circuit through port
the oil to the hydraulic tank. Above process (C) to release the abnormal pressure.
protects the work equipment circuit by restrict- q Using the repulsive force of spring (4) can
ing the maximum pressure. increase or decrease the set pressure.
q When increasing the set pressure, remove the
Operation cap nut to loosen the locknut and screw the
q Port (A) and port (C) are connected to the adjustment screw (5). When decreasing,
pump circuit and the drain circuit, respectively. loosen the adjustment screw (5).
Pressurized oil fills up port (B) after flowing
through the orifice of main valve (1). Pilot pop-
pet (3) is contacted with valve seat (2).

18 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Suction safety valve

1. Piston
2. Main valve q If abnormal pressure is generated in port (A)
3. Piston spring and reaches the set pressure of spring (6),
4. Valve seat poppet (5) opens to drain the pressurized oil in
5. Poppet port (C) through port (D) and outer circumfer-
6. Poppet spring ence (a) of suction valve (7).
7. Suction valve
8. Suction valve spring
9. Adjustment screw

Function
q This valve is installed in the bucket cylinder cir-
cuit of the work equipment control valve. When
the bucket lever is set to the neutral position, if
abnor mal pr ess ure is gener ated due to
impacts to the cylinder, the abnormal pressure
is relieved through this valve to protect the
hydraulic equipment such as cylinder from
damage.
q And if negative pressure is generated in the
cylinder circuit, this valve works as a suction
valve. q Opening of poppet (5) decreases the pressure
in port (C), and piston (1) moves to the right.
Operation Piston (1) contacts the tip of poppet (5) and the
pressurized oil is drained from port (D) through
orifice (b).
1. Operation as safety valve
q Port (A) and port (B) are connected to the cyl-
inder circuit and drain circuit, respectively.
q Pressurized oil in port (A) is conducted to port
(C) through piston (1) hole. Main valve (2) is
contacted against the left side due to the rela-
tion (d2) < (d3).
q The relation between the size of cross sec-
tional diameters (cross section areas) can be
presented as (d5) > (d4) > (d1) > (d3) > (d2).

WA200-6 19
SEN03255-00 10 Structure, function and maintenance standard

q Since the pressure in port (C) is lower than that Suction valve
in port (A), main valve (2) moves to the right
and the pressurized oil is conducted from port
(A) to port (B) to prevent generation of abnor-
mal pressure.
q Even if abnormal pressure is generated, suc-
tion valve (7) with the large cross sectional
diameter remains not operated because of the
relation (d1) < (d4).

1. Main poppet
2. Sleeve
3. Spring

Function
q This valve prevents to generate negative pres-
sure on the circuit.

Operation
2. Operation as suction valve q If negative pressure is generated in port (A) (lift
q If negative pressure is generated on the cylin- arm cylinder head) ([if a pressure lower than
der circuit, negative pressure is set on both that in the tank circuit port (B) is generated],
port (A) and port (C) because they are con- main poppet (1) is opened by the difference in
nected to each other. Suction valve ( 7) area between (d1) and (d2), and the pressur-
receives the pressurized oil by the difference in ized oil flows cylinder port (A) from tank port
area between (d4) and (d1). (B).
q When the differential pressure between port
(B) and port (A) increases beyond the set pres-
sure, suction valve (7) moves to the right. Thus
the pressurized oil flows from port (B) to port
(A) to prevent generation of negative pressure
in port (A).

20 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Operation of work equipment control valve


1. When lift arm and bucket spool are at the neutral position

Operation
q The pressurized oil flows to port (A) through q The bypass circuit is open since lift arm spool
pump (1) and the priority valve. And the maxi- (4) is at the neutral position. Thus, the pressur-
mum pressure is regulated by relief valve (2). ized oil in port (B) enters port (C) of the drain
q The bypass circuit is open since bucket spool circuit passing through in vicinity of the spool,
(3) is at the neutral position. Thus, the pressur- and returns to the hydraulic tank through the
ized oil in port (A) flows to port (B) passing filter.
through in vicinity of the spool.

WA200-6 21
SEN03255-00 10 Structure, function and maintenance standard

2. When lift arm spool is at raise position

Operation
q Pulling the work equipment control lever pulls
out lift arm spool (4) to set it to the raise posi-
tion.
q The pressurized oil from pump (1) flows to the
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder bottom through port (D).
q The pressurized oil on the cylinder head side
returns to the hydraulic tank through port (E)
and drain port (C). Thus, the lift arm is moved
upward.

22 WA200-6
10 Structure, function and maintenance standard SEN03255-00

3. When lift arm spool is at lower position

Operation
q Pushing the work equipment control lever
pushes in lift arm spool (4) to set it to the lower
position.
q The pressurized oil from pump (1) flows to the
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (B) pushes open
check valve (5).
q The pressurized oil from port (B) flows to the
cylinder rod side through port (E).
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (D)
and drain port (C). Thus, the lift arm is moved
downward.

WA200-6 23
SEN03255-00 10 Structure, function and maintenance standard

4. When lift arm spool is at float position

Operation
q Pushing the work equipment control lever fur- q As long as the bucket is contacting against the
ther from the lower position pushes in lift arm ground surface, the lift arm can be raised or
spool (4) to set it to the float position. lowered due to undulations on the ground sur-
q The pressurized oil from pump (1) flows to the face.
bypass circuit of lift arm spool (4) through the
bypass circuit of bucket spool (3).
q Since the pressurized oil in the bypass circuit
flows to the drain circuit by the spool, check
valve (5) cannot be pushed open.
q In addition, the lift arm descends by its own
weight since both the raise circuit (D) and
lower circuit (E) of the lift arm cylinder are con-
nected to the drain circuit.

24 WA200-6
10 Structure, function and maintenance standard SEN03255-00

5. When bucket spool is at tilt position

Operation
q Pulling the work equipment control lever pulls
out bucket spool (3) to set it to the tilt position.
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (G) flows to the
cylinder bottom side.
q The pressurized oil on the cylinder rod side
returns to the hydraulic tank through port (H)
and drain port (C). Thus, the bucket tilts.

WA200-6 25
SEN03255-00 10 Structure, function and maintenance standard

6. When bucket spool is at dump position

Operation
q Pushing the work equipment control lever
pushes in bucket spool (3) to set it to the dump
position.
q Since the bypass circuit is closed by the spool,
the pressurized oil from port (A) pushes open
check valve (7).
q The pressurized oil from port (H) flows to the
cylinder rod side.
q The pressurized oil on the cylinder bottom side
returns to the hydraulic tank through port (G)
and drain port (C). Thus, the bucket dumps.

26 WA200-6
10 Structure, function and maintenance standard SEN03255-00

PPC valve 1

a PPC: Abbreviation for Proportional Pressure Control

Work equipment PPC valve


Mono lever type

P: From HST charge pump P3: To lift arm valve (raise)


P1: To bucket valve (tilt) P4: To lift arm valve (lower, float)
P2: To bucket valve (dump) T: To hydraulic tank

WA200-6 27
SEN03255-00 10 Structure, function and maintenance standard

1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Piston
4. Rod 10. Retainer
5. Disc 11. Body
6. Nut (for connecting lever) 12. Filter

28 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Operation

1. When in neutral

1) Bucket PPC valve 2) Lift arm PPC valve


q Ports (PA) and (PB) of the control valve q Ports (PA) and (PB) of the control valve (lift
(bucket valve) and ports (P1) and (P2) of the arm valve) and ports (P3) and (P4) of the PPC
PPC valve are connected through fine control valve are connected through fine control hole
hole (f) of spool (1) to drain chamber (D). (f) of spool (1) to drain chamber (D).

WA200-6 29
SEN03255-00 10 Structure, function and maintenance standard

2. When in fine control mode


(neutral o fine control)
q If rod (4) and piston (9) are pushed by disc (5),
retainer (10) is pushed and spool (1) is also
pushed downward through metering spring (2).
q When fine control hole (f) is shut off from drain
chamber (D), almost simultaneously, it is con-
nected to pump pressure chamber (PP).
q The pilot pressurized oil from the HST charge
pump flows through fine control hole (f) and
port (P1) to port (PB).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (11) (where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)) does not change until
retainer (10) comes in contact with spool (1).
q Metering spring (2) is compressed in propor-
tion to the stroke of the control lever.
q Pressure in port (P1) also increases in propor-
tion to the stroke of the control lever.
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.

30 WA200-6
10 Structure, function and maintenance standard SEN03255-00

3. When in fine control mode 4. When lever is operated to stroke end


(when control lever is returned) q Disc (5) and rod (4) push down piston (9) and
q As disc (5) begins to return, the force of center- retainer (10) pushes down spool (1).
ing spring (3) and the pressure in port (P1) q Fine control hole (f) is disconnected from drain
push up spool (1). chamber (D) and connected to the pump pres-
q Because of this, fine control hole (f) is con- sure chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot pressure oil from the HST charge
ized oil at port (P1) is released. pump flows through fine control hole (f) and
q If the pressure in port (P1) went abnormally port (P1) into chamber (PB) to push the control
low, spool (1) is pushed down by metering valve spool.
spring (2). q The oil returning from chamber (PA) flows
q Fine control hole (f) is disconnected from drain through port (P2) and fine control hole (f') into
chamber (D) and almost simultaneously con- drain chamber (D).
nected to the pump pressure chamber (PP).
q The pump pressure is supplied until the pres-
sure in port (P1) recovers to a pressure equiv-
alent to the position of the lever.
q When the control valve spool returns, the pres-
surized oil in drain chamber (D) flows in
through fine control hole (f') of the valve which
is not in operation and flows through port (P2)
into chamber (PA).

WA200-6 31
SEN03255-00 10 Structure, function and maintenance standard

5. When lift arm is "float"


q If disc (5) pushes down rod (4) and piston (9)
on port (P4) "lower" side, the detent starts
operation before the stroke end. (the operating
effort of the lever becomes heavy.)
q If rod (4) is pushed down further, the detent
operates to keep the lift arm in "float" state
even if the lever is released.
q At the same time, the control valve is also
moved to the "float" position to keep the lift arm
in float condition.

6. When "float" state of lift arm is reset


q When returning disc (5) from the "float" posi-
tion, the rod is pushed down with a force larger
than absorptive power of the solenoid.
q The "float" state also can be reset and the
lever can be returned to the "neutral" position
by turning off the current in the solenoid (de-
energizing the solenoid).

q The lift arm raise and bucket tilt operations are


carried out similarly to the above.

32 WA200-6
10 Structure, function and maintenance standard SEN03255-00

WA200-6 33
SEN03255-00 10 Structure, function and maintenance standard

Attachment PPC valve (if equipped)

a For the details of operation, see the paragraph of "Work equipment PPC valve".

34 WA200-6
10 Structure, function and maintenance standard SEN03255-00

P: From self pressure reducing valve


P1: To attachment valve
P2: To attachment valve
T: To hydraulic tank

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter

Unit: mm
No. Item Criteria Remedy
Standard size Repair limit
Free length x
Installed
Outside Installed load Free length Installed load
8 Centering spring
diameter
length If damaged or
deformed, replace
41.1 x 15.5 29 36.3 N — 29.0 N spring
{3.7 kg} {2.96 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22 {1.7 kg} — {1.36 kg}

WA200-6 35
SEN03255-00 10 Structure, function and maintenance standard

Lock valve 1

1. Lever
2. End cap
3. Ball
4. Seat
5. Body

Outline
q The lock valve is installed between the HST
charge pump and work equipment PPC valve.
As the work equipment lock lever is set to the
"Lock" position, this valve, in conjunction with
the work equipment lock lever, cuts off the oil
of the PPC circuit to disable the work equip-
ment operation.

36 WA200-6
10 Structure, function and maintenance standard SEN03255-00

Accumulator (for PPC circuit) 1

1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port

Outline
q The accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.

Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charged pressure 1.18(+0.2/0) {12(+2/0)}
(MPa {kg/cm2}) (at 80°C)
Max. pressure used
3.92 {40}
(MPa {kg/cm2})

WA200-6 37
SEN03255-00 10 Structure, function and maintenance standard

ECSS valve 1
(if equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System

P: From work equipment pump


T: To hydraulic tank
A: From lift cylinder bottom
B: From lift cylinder head
SP: To accumulator (for ECSS)

38 WA200-6
10 Structure, function and maintenance standard SEN03255-00

1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve

WA200-6 39
SEN03255-00 10 Structure, function and maintenance standard

Accumulator (for ECSS) 1

(if equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston

Function
q The accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.

Specifications
Gas used Nitrogen gas
Amount of gas (cc) 2,000
Charged pressure 1.67 ± 0.05 {17 ± 0.5}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
20.6 {210}
(MPa {kg/cm2})

40 WA200-6
10 Structure, function and maintenance standard SEN03255-00

WA200-6 41
SEN03255-00

WA200-6 Wheel loader


Form No. SEN03255-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

42
SEN03256-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Work equipment
Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 4
Bucket positioner and boom kick-out .............................................................................................................. 6
Work equipment cylinder .............................................................................................................................. 12

WA200-6 1
SEN03256-00 10 Structure, function and maintenance standard

Work equipment linkage 1

2 WA200-6
10 Structure, function and maintenance standard SEN03256-00

1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link

Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing and pin size Shaft Hole clearance limit
7 at each end of bucket link –0.030 +0.174 0.130 –
65 1.0
–0.076 +0.100 0.250
Clearance between bushing and pin –0.030 +0.174 0.130 –
8 connecting lift arm and bucket
65
–0.076 +0.100 0.250
1.0

Clearance between bushing and pin –0.030 +0.174 0.130 –


9 connecting lift arm and frame
75
–0.076 +0.100 0.250
1.0

Clearance between bushing and pin


–0.030 +0.174 0.130 – Replace
10 connecting bucket cylinder bottom 70
–0.076 +0.100 0.250
1.0
and frame (Replace pin when
it has scuff marks,
Clearance between bushing and pin too.)
–0.030 +0.174 0.130 –
11 connecting bucket cylinder rod and 70
–0.076 +0.100 0.250
1.0
bell crank

12 Clearance between bushing and pin


connecting bell crank and lift arm
75
–0.030
–0.076
+0.174
+0.100
0.130 –
0.250
1.0

Clearance between bushing and pin


–0.030 +0.174 0.130 –
13 connecting lift cylinder rod and lift 65
–0.076 +0.100 0.250
1.0
arm
Clearance between bushing and pin
–0.030 +0.174 0.130 –
14 connecting lift cylinder bottom and 65
–0.076 +0.100 0.250
1.0
frame
Width of boss Width of hinge
Standard
Standard Standard clearance
15 Connecting
and frame
part of bucket cylinder
size
Tolerance
size
Tolerance

0
80 83 ±1.5 1.5 – 5.0
-0.5
Adjust shim so that
16 Connecting
frame
part of lift arm and
85 — 89 ±1.5 2.5 – 5.5 clearance will be
below 1.5 mm on
17 Connecting
bucket
part of lift arm and
85 — 88
+3.0
0
3.0 – 6.0 each side

18 Connecting
bucket
part of bucket link and
85 ±1.0 88
+3.0
0
2.0 – 7.0

19 Connecting
frame
part of lift cylinder and
85
0
–0.5
89 ±1.5 2.5 – 6.0

20 Connecting
bucket link
part of bell crank and
85 ±1.0 88 ±1.5 0.5 – 5.5
Replace
21 Connecting
arm
part of bell crank and lift
148 ±0.5 151 ±1.5 1.0 – 5.0

22 Connecting part of bucket cylinder


and bell crank
80
0
-0.5
88 ±1.5 6.5 – 10.0 Adjust shim so that
clearance will be
below 1.5 mm on
23 Connecting
cylinder
part of lift arm and lift
85 — 89 ±1.5 2.5 – 5.5 each side

WA200-6 3
SEN03256-00 10 Structure, function and maintenance standard

Bucket 1

1. Bucket 3. Bucket teeth (if equipped)


2. Bolt-on cutting edge

Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
4 Wear of cutting edge (Thickness)
25.4 15
Reverse or replace

5 Wear of cutting edge (Length) 62 5

6 Wear of bucket teeth 35 18 Replace

Clearance in adapter mounting


7 parts
Max. 0.5 — Adjust or replace

4 WA200-6
10 Structure, function and maintenance standard SEN03256-00

WA200-6 5
SEN03256-00 10 Structure, function and maintenance standard

Bucket positioner and boom kick-out 1

1. Bucket positioner proximity switch 4. Bucket cylinder


2. Boom kick-out proximity switch (if equipped) 5. Lift arm
3. Bar 6. Plate (if equipped)

Unit: mm
No. Check item Criteria Remedy
Clearance on bucket positioner
7 proximity switch
3–5
Adjust
Clearance on boom kick-out
8 proximity switch
3–5

6 WA200-6
10 Structure, function and maintenance standard SEN03256-00

Outline

Bucket positioner
q The bucket positioner is driven electrically.
When the bucket is returned to an angle from
the dump position to the tilt position, the bucket
positioner returns the work equipment (bucket)
control lever from the "tilt" position to the "hold"
position to automatically stop the bucket at a
proper digging angle.
q Bar (3) is fixed to the rod side of bucket cylin-
der (4). And proximity switch (1) is fixed to the
cylinder side.
q Moving the work equipment (bucket) control
lever from "dump" position to "tilt" position
moves the rod of bucket cylinder (4) toward the
machine front side.
As bar (3) moves a specific distance, proximity
switch (1) detects that it is away from the sens-
ing face, and returns the work equipment
(bucket) control lever to "hold" position.

Boom kick-out
(if equipped)
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (6) is fixed to lift arm (5). And proximity
switch (2) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (5) upward.
As plate (6) moves a specific distance, proxim-
ity switch (2) detects that it is away form the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.

WA200-6 7
SEN03256-00 10 Structure, function and maintenance standard

Operation of proximity switch

When bucket is tilted

q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the tilt position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.

8 WA200-6
10 Structure, function and maintenance standard SEN03256-00

a The power supply for detent solenoid (6) oper-


ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alter-
nator relay (11) as long as the engine is
stopped.
As the result, the work equipment (bucket)
control lever (7) cannot be moved and held in
the tilt position as long as bar (2) is positioned
in sensing face of proximity switch (1).

Function of proximity switch

When object of sensing is over sensing face of


proximity switch

Lamp of proximity switch Turned ON

Bucket positioner relay ON

Work equipment PPC valve detent


Power ON
solenoid circuit
Work equipment PPC valve detent
Energized
solenoid

When object of sensing is apart from sensing


face of proximity switch

Lamp of proximity switch Turned OFF

Bucket positioner relay OFF

Work equipment PPC valve


Power OFF
detent solenoid circuit
Work equipment PPC valve detent
De-energized
solenoid

q As the bucket is tilted and moved away from


the position set by the positioner, in other
words, as bar (2) moves away from the sens-
ing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket posi-
tioner relay (4) is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held bucket spool (8) receives the reaction
force of spring (9) and returns work equipment
(bucket) control lever (7) to "hold" position.

WA200-6 9
SEN03256-00 10 Structure, function and maintenance standard

When lift arm is raised

q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the raise position moves spool (8) to
moves on to the sensing face of proximity the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.

10 WA200-6
10 Structure, function and maintenance standard SEN03256-00

a The power supply for detent solenoid (6) oper-


ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is cut off since L sig-
nal from alternator (10) is not sent to alternator
relay (11) as long as the engine is stopped.
As the result, the work equipment (lift arm)
control lever (7) cannot be moved and held in
the raise position as long as plate (2) is posi-
tioned in sensing face of proximity switch (1).

Function of proximity switch

When object of sensing is apart from sensing


face of proximity switch

Lamp of proximity switch Turned ON

Boom kick-out relay ON

Work equipment PPC valve detent


Power ON
solenoid circuit
Work equipment PPC valve detent
Energized
solenoid

When object of sensing is over sensing face of


proximity switch

Lamp of proximity switch Turned OFF

Boom kick-out relay OFF

Work equipment PPC valve detent


Power OFF
solenoid circuit
Work equipment PPC valve detent
De-energized
solenoid

q As lift arm (3) is raised and moved away from


the position set by the boom kick-out, namely
as plate (2) moves away from the sensing face
of proximity switch (1), the lamp of proximity
switch (1) lamp goes off and boom kick-out
relay (4) is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held lift arm spool (8) receives the reaction
force of spring (9) and returns work equipment
(lift arm) control lever (7) to the "hold" position.

WA200-6 11
SEN03256-00 10 Structure, function and maintenance standard

Work equipment cylinder 1

Lift cylinder

Bucket cylinder

Unit: mm
No. Check item Criteria Remedy
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between –0.030 +0.262 0.097 –
1 piston rod and bushing Lift 65 0.666 Replace bushing
–0.104 +0.067 0.366

Bucket 65 –0.030 +0.262 0.097 – 0.666


–0.104 +0.067 0.366

12 WA200-6
10 Structure, function and maintenance standard SEN03256-00

WA200-6 13
SEN03256-00

WA200-6 Wheel loader


Form No. SEN03256-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

14
SEN03257-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Cab and its attachments


Cab ................................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4

WA200-6 1
SEN03257-00 10 Structure, function and maintenance standard

2 WA200-6
10 Structure, function and maintenance standard SEN03257-00

Cab 1

1. Front working lamp


2. Radio antenna
3. Door (left)
4. Air conditioner external air filter
5. Front glass
6. Front wiper
7. KOMTRAX GPS antenna (if equipped)
8. KOMTRAX communication antenna (if equipped)
9. Door (right)
10. Rear wiper

WA200-6 3
SEN03257-00 10 Structure, function and maintenance standard

Air conditioner 1

Air conditioner piping diagram 1

4 WA200-6
10 Structure, function and maintenance standard SEN03257-00

1. Hot water take-out piping Specifications


2. Compressor Refrigerant used R134a
3. Condenser
4. Receiver Refrigerant refilling level (g) 1,150
5. Hot water return piping
6. Refrigerant piping
7. External air filter
8. Internal/external air changeover damper
9. Blower unit
10. Air conditioner unit
11. Dual pressure switch
12. Air outlet duct
13. Cool and hot box (if equipped)
14. Internal air filter

WA200-6 5
SEN03257-00 10 Structure, function and maintenance standard

Refrigerant circuit diagram

1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
6. Dual pressure switch

Table of tightening torque for refrigerant piping adapter


Unit: Nm {kgm}
No. Check item Criteria Remedy
12 – 15 {1.2 – 1.5}
7 Air conditioner unit refrigerant inlet side
(screw size: M16 x 1.5)
30 – 35 {3.1 – 3.6}
8 Air conditioner unit refrigerant outlet side
(screw size: M24 x 1.5)
8 – 12 {0.8 – 1.2}
9 Receiver refrigerant pipe set bolt
(screw size: M16 x 1.0)
Retighten
20 – 25 {2.0 – 2.6}
10 Compressor refrigerant piping lock bolt (screw size: M8 x 1.25)
20 – 25 {2.0 – 2.6}
11 Condenser refrigerant inlet side (screw size: M22 x 1.5)
12 – 15 {1.2 – 1.5}
12 Condenser refrigerant outlet side (screw size: M16 x 1.5)

6 WA200-6
10 Structure, function and maintenance standard SEN03257-00

Air conditioner unit 1

A: From receiver Outline


B: To compressor q The vertical air conditioner unit on which evap-
C: Hot water inlet orator (1) and heater core (2) is synchronized
D: Hot water outlet with the blower and intake unit to generate cool
and hot air.
1. Evaporator q The temperature adjusting switch on the air
2. Heater core conditioner panel controls air mix dampers (3)
3. Air mix damper (upper) and (4) to adjust the spurting out temperature.
4. Air mix damper (lower)
5. Expansion valve Cooler
6. Blower controller
q The cooler circulates refrigerant through evap-
7. Blower motor relay
orator (1) to cause heat exchange (dehumidifi-
8. Compressor clutch relay
cation and cooling).
9. Air mix damper actuator
q Air taken in by the blower and intake unit is
10. Evaporator temperature sensor
cooled with evaporator (1) and then blown out
11. Dual pressure switch
from the duct and grill.

Heater
q The heater circulates engine coolant in heater
core (2) to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core (2) and then blown out
through the duct and grill.

WA200-6 7
SEN03257-00 10 Structure, function and maintenance standard

Functions of major components


Evaporator Air mix damper actuator
q Evaporator fin is cooled by the low-pressure, q It starts the built-in motor receiving signal cur-
low-temperature refrigerant gas being sent rent from the air conditioner panel in order to
from the expansion valve. Air from the blower open or close the air mix damper through the
motor is cooled and dehumidified when pass- link mechanism.
ing through the fin. q The motor rotating direction is determined as
the air conditioner panel reads the position of
Heater core the potentiometer being built in the actuator.
q Fin of the heater core is heated by the hot This reading is done as the target temperature
water (cooling water) being sent from the is set from the temperature adjustment switch
engine. Air from the blower motor is heated as on the air conditioner panel.
it passes through the fin. q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
Expansion valve motor, moves away or signal current from the
q This valve converts high-pressure, high-tem- air conditioner panel is turned "OFF".
perature liquid refrigerant from the receiver to
low-pressure, low-temperature misty refriger- Evaporator temperature sensor
ant through the throttling function. q In order to prevent freezing of the evaporator, it
It controls flow rate of refrigerant by changing senses the evaporator temperature and sends
level of throttling depending on the thermal necessary signals to the air conditioner panel.
load in the operator's cab. The signal sent to the air conditioner panel is
used to control the compressor. As the result,
Blower controller temperature of the air blown out of the grill is
q It controls the blower motor speed receiving adjusted depending on the volume of refriger-
signal current from the air conditioner panel. ant circulated in the evaporator.

Blower motor relay Dual pressure switch


q Signal current from the air conditioner panel q If abnormally low or high pressure was gener-
controls the relay coil. As the relay coil is ener- ated in the refrigerant circulation circuit, this
gized and the switch is turned "ON", power is switch releases the magnet clutch of the com-
supplied to the blower motor. pressor to protect a series of cooler-related
equipment.
Compressor clutch relay
q Signal current from the air conditioner panel
dual pressure switch is used for controlling the
relay coil. As the relay coil is energized and the
switch is turned "ON", the magnet clutch of the
compressor is connected.

LA: 0.20 MPa {2 kg/cm2}


LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}

8 WA200-6
10 Structure, function and maintenance standard SEN03257-00

Blower and intake unit 1

1. Blower motor assembly Functions of major components


2. Internal/external air changeover damper actuator Blower motor assembly
3. Internal/external air changeover damper q It suctions air by rotating the fin installed on the
blower motor. And it is also used for sending
the absorbed air to the evaporator and heater
core.

Internal/external air changeover damper actua-


tor
q Receiving signal current from the air condi-
tioner panel, it starts the built-in motor to open
or close the internal/external air changeover
damper through the link mechanism.
q The motor rotation direction is determined from
the internal/external air changeover switch on
the air conditioner panel.
q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
motor, moves away or signal current from the
air conditioner panel is turned "OFF".

WA200-6 9
SEN03257-00 10 Structure, function and maintenance standard

Compressor 1

A: From air conditioner unit Function


B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature misty
refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.

Specifications
Number of cylinders –
7 – 29.3 x 27.4
Bore x Stroke (mm)

Piston capacity (cc/rev) 129.2

Allowable maximum speed


4,000
(rpm)

Refrigerant oil used Sanden: SP-10

Refrigerant oil refilling volume


135
(cc)

10 WA200-6
10 Structure, function and maintenance standard SEN03257-00

Condenser 1

A: From compressor Function


B: To receiver q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
compressor.

a If the fin crushes or is clogged with dusts, heat


exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.

Specifications
Fin pitch (mm) 1.5
Total heat dissipation area (m )
2
6.55
Max. pressure used
3.6 {36}
(MPa {kg/cm2})

WA200-6 11
SEN03257-00 10 Structure, function and maintenance standard

Receiver 1

A: From condenser Function


B: To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the con-
1. Sight glass denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.

Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300

12 WA200-6
10 Structure, function and maintenance standard SEN03257-00

WA200-6 13
SEN03257-00 10 Structure, function and maintenance standard

Air conditioner panel 1

Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Spurting out All segments below applicable level come
1 See above drawing
temperature on (8-step display)
Gauge
Air blasting All segments below applicable level come
2 See above drawing
volume on (4-step display)
The display indicates which is currently
Circulation of When circulating Liquid
taking place - internal air circulation or Black
internal air and internal air and crystal
3 external air introduction - responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air
Turns "ON" air conditioner switch, this lamp
4 Air conditioner conditioner switch
lights up.
is "ON"

Switch block
No. Switch name Function Operation
Circulation of
This switch is used to select either the circulation of internal air or
internal air
Internal/external air introduction of external air
5 IO
changeover switch (pilot display on the display unit is switched depending on the switch
Introduction of
setting)
external air
6 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
It turns on or off main power supply of the air conditioner.
7 Main power switch ON: Settings done during "OFF" are indicated on the display unit. OFF io ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO io HI
(adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It controls the spurting out temperature
9 IO
switch (8-step adjustment)
High temperature

14 WA200-6
10 Structure, function and maintenance standard SEN03257-00

Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.

Input and output signals


JAE IL-AG5-14P [CN-C48] JAE IL-AG5-22P [CN-C47]
Input and Input and
Pin No. Signal name output Pin No. Signal name output
signals signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
Internal/external air changeover 3 Blower motor relay Input
3 Input
damper actuator limiter
Internal/external air changeover
4 External air temperature sensor Input 4 damper actuator output 1 Output

5 Evaporator temperature sensor Input 5 Internal/external air changeover Output


damper actuator output 2
6 Internal air temperature sensor Input
6 Mode selector actuator output 2 Output
7 Starting switch (ON) Input
7 Mode selector actuator output 1 Output
8 Night lamp signal Input
8 Air mix damper actuator output 2 Output
9 NC —
9 Air mix damper actuator output 1 Output
10 NC —
10 Actuator potentiometer power supply —
11 NC — (5 V)
12 NC — 11 NC —
13 Day light sensor 2 Input 12 NC —
14 Day light sensor 1 Output 13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
Air mix damper actuator
18 potentiometer Input

19 Mode selector actuator potentiometer Input


20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —

WA200-6 15
SEN03257-00

WA200-6 Wheel loader


Form No. SEN03257-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

16
SEN03258-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Electrical system, Part 1


Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 6

WA200-6 1
SEN03258-00 10 Structure, function and maintenance standard

Machine monitor system 1

Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors controls the machine setting and adjustment functions are provided
condition with the sensors installed to various using the character display and the machine
parts of the machine, and then sends the result monitor mode selector switch, which is the
as network information to the machine monitor, operation switch of the character display.
which displays the information to notify the 1) Switching of traction level
operator of the machine condition. 2) Switching of HST reverse travel gear shift-
ing pattern
q The machine monitor displays the information 3) Display the odometer
in the operator mode or service mode. 4) Resetting the filter or oil replacement time
5) Input the telephone number
q The operator mode is used to display the infor- 6) Selecting the language
mation to the operator normally. The major 7) Adjusting the illuminance of nighttime light
functions used in the service mode are as fol- 8) Travel speed/engine speed display select-
lows. ing function
9) Function for setting display/no-display of
1. Items always displayed travel speed or engine speed to the char-
q Meters (speedometer or engine tachome- acter display
ter)
q Gauges (engine coolant temperature
gauge, HST oil temperature gauge and
fuel gauge)
q Pilot indicators
q Service meter

The following items are displayed accord-


ing to the set state of the optional device
selecting function.
q Travel speed or engine speed indication
on the character display

2. Items displayed when abnormality is detected


q Caution lamps
q Action code (while an action code is dis-
played, if the machine monitor mode
selector switch (>) is pressed and
released, the failure code (6 digits) is dis-
played.)

3. At the replacement period of a filter or oil, the


character display displays that filter or oil.
(maintenance monitoring function)

2 WA200-6
10 Structure, function and maintenance standard SEN03258-00

q The service mode function is provided for the 10. Machine serial number input function
ease of troubleshooting for the controllers on Enters the machine serial number to identify
the network (including the machine monitor the machine.
itself). The major functions used in this mode
are as follows. 11. Model selection function
Enters the information of applicable model.
1. Electrical system failure history display func-
tion 12. Initialize function
The electrical system failures of each controller Sets the machine monitor to the state set when
saved in the machine monitor are displayed. the machine is delivered.
The information of those failures is also
deleted with this function.

2. Mechanical system failure history display func-


tion
The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.

3. Real-time monitoring function


The input and output signals recognized by
each controller on the network are displayed in
real time.

4. Engine reduced-cylinder function


This function is used for the purpose of speci-
fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.

5. No injection cranking function


Before restarting engine after a long-term stor-
ing of the machine, this function is used to
lubricate the engine internally.

6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.

7. Maintenance monitoring function


Changes the filter or oil replacement time and
makes ON/OFF selection of the function.

8. Operating information display function


Displays fuel consumption per operating hour.

9. Optional device selecting function


Verifies the installation of optional devices or
changes their setting.

WA200-6 3
SEN03258-00 10 Structure, function and maintenance standard

System circuit diagram


a Items marked with "*1" in drawing may or may not installed.

4 WA200-6
10 Structure, function and maintenance standard SEN03258-00

WA200-6 5
SEN03258-00 10 Structure, function and maintenance standard

Machine monitor 1

1. HST oil temperature gauge 21. Quick coupler operation pilot lamp (*2)
2. HST oil temperature caution lamp 22. Cooling fan reverse rotation pilot lamp
3. Engine coolant temperature gauge 23. Maintenance caution lamp
4. Engine coolant temperature caution lamp 24. Parking brake reminder caution lamp
5. Speedometer or engine tachometer 25. Battery charge circuit caution lamp
6. Turn signal pilot lamp (left) 26. Steering oil pressure caution lamp (*2)
7. Head lamp high beam pilot lamp 27. Emergency steering pilot lamp (*2)
8. Turn signal pilot lamp (right) 28. Meter display pilot lamp
9. Fuel level caution lamp 29. Character display portion
10. Fuel gauge 30. Preheating pilot lamp
11. Central warning lamp 31. Directional selector switch actuation pilot lamp
12. Brake oil pressure caution lamp (*1)
13. Engine oil pressure caution lamp 32. Economy operation display lamp
14. Water separator caution lamp 33. Shift hold pilot lamp (*1)
15. Engine oil level caution lamp (*1) 34. S mode operation pilot lamp
16. Radiator coolant level caution lamp 35. Traction control operation pilot lamp
17. HST oil filter clogging caution lamp 36. Travel speed range selector switch position
18. Air cleaner clogging caution lamp (*1) pilot lamp
19. Parking brake pilot lamp 37. Directional lever position pilot lamp
20. Brake oil temperature caution lamp

*1: Not used by this model


*2: If equipped

6 WA200-6
10 Structure, function and maintenance standard SEN03258-00

List of items displayed on monitor 1


Condition for judging that the engine is running:
If 2 or more are met in the following 3 conditions, the engine is judged running when the abnormality in the
CAN communication occurs and the charge level exceeds the specified level.
1. Turning "ON" of the starting switch is recorded (IGN-C signal was entered)
2. Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above
after that)
3. Engine speed is 500 rpm or above
Lamp Lamp period Alarm buzzer Operating condition Buzzer period Priority

w: Intermittent Warning for dangerous Period: 1,600 msec.


Q: ON — condition (error or caution ON: 800 msec. 1
sounds
message is generated) OFF: 800 msec. (duty 50%)
Period: 1,600 msec. Caution for erroneous Period: 240 msec.
A: Intermittent
w: Flashing ON: 800 msec. operation (when an irregular ON: 80 msec. 2
OFF: 800 msec. (duty 50%) sounds operation is done) OFF: 160 msec.
Period: 240 msec.
E: Canceling Set cancellation such as
A: Intermittent ON: 80 msec. sounds calibration (inoperative state) ON: 1,000 msec. (1 time) 3
OFF: 160 msec.
Completion of setting such ON: 100 msec.
E: Separately e: Completion
— as calibration (when normally OFF: 160 msec. 4
set conditions sounds
ended) ON: 100 msec. (1 time)

Detecting Operating condition


time
(sec) Engine stopped Engine is running

Display color
Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Category No. Item Device Operating condition Remarks

Display of

Display of
Detection

message

message
Reset

lamp

lamp
Turned ON with errors (E03
and E02) of each controller,
When error occurs E E E E E E E E simultaneously displaying the
message on the character
Central

Red
11 Central warning LED display.
warning lamp
For other than above, see
"Operating condition, central
— — — — — —
warning lamp" of other
items.
White
When lamp switch is other
Back light — Back light LED — — — — — —
than "OFF"

White range: 30 – 105°C


Other than below — — — — — — Red range: 105 – 135°C
Pointer:
Movement When the sensor is
1 HST oil
Red

Alarm: 105°C or above 10 1 w Q Q B@CRNS w Q Q B@CRNS disconnected or hot short-


2 temperature
Caution circuited: Max
lamp: LED When abnormality is When sensor was
detected (out of input signal 20 5 — — — DGH1KX — — — DGH1KX disconnected or hot short-
range) circuited: Min

Other than below — — — — — —

White range: 50 – 102°C


Alarm: 102°C or above 3 0 — Q — — Q — Red range: 102 – 135°C
Gauges and Pointer:
meters Movement When the sensor is
3 Engine coolant
Red

Alarm: 105°C or above w Q Q B@BCNS w Q Q B@BCNS disconnected or hot short-


4 temperature
Caution circuited: Max
lamp: LED When sensor was
When abnormality is disconnected or hot short-
— — — CA144 — — — CA144
detected (high temperature) circuited: Min

When abnormality is
— — — CA145 — — — CA145
detected (low temperature)

When engine speed display (selectable with the machine


Engine speed — — — — — — monitor setting)
is selected
Pointer:
5 —
Movement When a communication error
When travel speed display is is detected, the system
Travel speed — — — — — —
selected displays "0".

Other than below — — — — — — Max: 10 z


Min: 85 z
Pointer:
Movement Min. 62 z 10 1 — Q — — Q —
Gauges and 9 When the sensor is grounded:
Red

Fuel level
meters 10 Full
Caution
When abnormality is When sensor was
lamp: LED
detected (input voltage is 4 V disconnected or hot short-
10 2 — — — DJF1KA — — — DJF1KA circuited: Empty
or above and no incoming
IGN-C signal is detected)

WA200-6 7
SEN03258-00 10 Structure, function and maintenance standard

Detecting Operating condition


time
(sec) Engine stopped Engine is running

Display color
Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Category No. Item Device Operating condition Remarks

Display of

Display of
Detection

message

message
Reset

lamp

lamp
Operates when charging
Service meter normally at 1 : 1 to the clock — — — — — — Displays various codes and
time

Black
Character items according to the
29 LCD
display machine condition and switch
Converts travel speed pulse operation.
Odometer — — — — — —
into travel distance

x 100 r/min

Green
When engine speed display (setting of a desired value is
Engine speed 0 0 — Q — — Q —
is selected available from the machine
monitor)
Unit 28 LED
km/h or MPH

Green
When travel speed display is (setting of a desired value is
Travel speed 0 0 — Q — — Q —
selected available from the machine
monitor)
When F is selected (neutral

Green Green Green Green Green Green Orange Green


F LED safety is displayed as engine 1 0 A Q Q — Q —
is stopped)
Directional
37 lever N LED When N is selected 0 0 — Q — — Q —
position
When R is selected (neutral
R LED safety is displayed as engine 1 0 A Q Q — Q —
is stopped)
When error occurs in
Items related
When 4th gear speed is communication, condition is
to gear 4 LED 0 0 — Q — — Q —
selected held until starting switch is
shifting
turned "OFF".
Travel When 3rd gear speed is
speed 3 LED 0 0 — Q — — Q —
selected
range
36
selector
switch When 2nd gear speed is
2 LED 0 0 — Q — — Q —
position selected

When 1st gear speed is


1 LED 0 0 — Q — — Q —
selected
When turn signal lever and Hazard lamp operates when
6
Turn signal LED hazard lamp switch signal is 0 0 — Q — — Q — starting switch is turned
8
input "OFF".
When head lamp is set to
Head lamp high high beam (when head lamp
Blue
7 LED 0 0 — Q — — Q —
beam is "ON" and dimmer switch
is "ON")

Normal oil pressure


— — — — — —
(CLOSE)

Below set pressure (OPEN)


(detection time continues)
1 1 — Q — w Q Q
Brake oil and 30 seconds after engine
Red

12 LED is started (no detection time)


pressure
Below set pressure (OPEN)
(detect time continues) and
after 30 seconds elapsed 5 1 — — — w Q Q 2G40ZG
since engine was started
(no detection time)

Normal oil pressure


— — — — — —
(CLOSE)
Engine oil
Red

13 LED
pressure
Other Low oil pressure (OPEN) w Q Q B@BAZG w Q Q B@BAZG
symbols

Normal — — — — — —
Water
Red

14 LED
separator
Water mixing with fuel — Q — CA418 — Q — CA418

Normal coolant level


— — — — — —
(CLOSE)
Radiator
Red

16 LED
coolant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK

Normal (OPEN) — — — — — —

Clogging (CLOSE) (HST oil


temperature 50°C or above
HST oil filter 10 2 — — — — Q — 6091NX
Red

17 LED and no abnormality


clogging detected)
When abnormality is
detected (clogging was KEY
3 — — — DHTCL6 — — — DHTCL6
detected as engine was OFF
stopped)

8 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Detecting Operating condition


time
(sec) Engine stopped Engine is running

Display color
Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Category No. Item Device Operating condition Remarks

Display of

Display of
Detection

message

message
Reset

lamp

lamp
Operation (OPEN) — Q — — Q —

Released (CLOSE) — — — — — —

Red
19 Parking brake LED
Engine is running, parking
brake is operated and the
0 0 — — — A Q Q
directional lever is at any
position other than "N"

Other than below — — — — — —

Temperature rise (oil


temperature: Min. 120°C 5 5 — Q — — Q —
(alarm)
Temperature rise (1. or 2.)
1. Oil temperature 130°C or To be released if the oil
Brake oil above temperature is detected

Red
20 LED 5 5 w Q Q B@C6NS w Q Q B@C6NS
temperature 2. Oil temperature 125°C or consecutively at lower than
above and travel speed 125°C for 5 sec.
35 km/h or above

When abnormality is
— — — DGR2KB — — — DGR2KB
detected (ground fault)

When abnormality is
detected (disconnection or — — — DGR2KZ — — — DGR2KZ
hot short-circuit)
Alarm buzzer is sounded
Other than below — — — — — — when connection of quick
coupler is reset. Error
Quick coupler

Red
21 LED message is simultaneously
operation
When quick coupler is displayed on the character
0 0 A Q — Remarks A Q — Remarks display.
disconnected
"PIN DISCONNECT"

Normal 0 0 — — — — — —
Error message is displayed on
the character display when

Orange
Cooling fan
22 LED Reverse 0 0 — Q — Remarks — Q — Remarks long as reverse rotation of fan
reverse rotation
is continued.
"COOLING FAN REVERSE"
Selecting reverse rotation 0 0 — w — — w —
Other
symbols
Ordinary — — — — — —
Message is simultaneously
Red

23 Maintenance LED displayed on the character


30 hours or less before display.
maintenance or — Q — E — Q — E
maintenance time
Error message is displayed on
the character display as long
as parking brake is left
Other than below — — — — — — unapplied.
"The alarm continues as long
as starting switch is turned
Parking brake
Red

24 LED "OFF".
reminder
This function can be enabled
when "MECHA" is selected for
When parking brake is left "7. PKG BRAKE" from the
0 0 w Q Q Remarks — — —
unapplied (CLOSE) "Option device selecting
function" of the machine
monitor.
If abnormality is detected
Normal voltage — — — — — — when starting switch is turned
"ON", alarm is continued even
Engine is running, alternator after engine is started.
Battery charge voltage is below the
Red

25 LED 30 1 — — — w Q Q AB00MA
circuit specified level, and no <Voltage hysteresis>
incoming ING-C is present. Judgment for Abnormal o
When abnormality is Normal: 12 V or above
detected (unmatched engine 3 1 w Q Q AB00L6 — — — Judgment for Normal o
condition and the signal) Abnormal: 5 V or below

This function can be enabled


Oil pressure normal (OPEN) — — — — — — when "ADD" is selected for "2.
EMERG S/T" from the
"Optional device selecting
Steering oil
Red

26 LED 0.5 0 — Q — — Q — function" of the machine


pressure
monitor.
Low oil pressure (CLOSE) *: The function is reset
(*) immediately when engine
3 — — — w — Q DDS5L6
1 is stopped.
This function can be enabled
Oil pressure normal (OPEN) 0 0 — Q — — Q — when "ADD" is selected for "2.
Green

Emergency EMERG S/T" from the


27 LED
steering "Optional device selecting
Low oil pressure (CLOSE) — — — — — — function" of the machine
monitor.

WA200-6 9
SEN03258-00 10 Structure, function and maintenance standard

Detecting Operating condition


time
(sec) Engine stopped Engine is running

Display color
Individual display

Individual display
Central warning

Central warning
Alarm buzzer

Alarm buzzer
Category No. Item Device Operating condition Remarks

Display of

Display of
Detection

message

message
Reset

lamp

lamp
Other than below — — — — — —

Red
30 Preheating LED
When preheater is turned
0 0 — Q — — Q —
ON

Other than below 0 0 — — — — — —

Green
Economy
32 LED
operation
Economy mode operation 0 0 — Q — — Q —
Other
symbols
Other than below — — — — — —

Green
S mode
34 LED The lamp goes off when
operation
S mode operation is traction control is reset from
0 0 — Q — — Q —
selected max. traction switch. When
traction control is reset with
max. traction switch, the lamp
Other than below — — — — — — is lit again when directional

Green
Traction control lever position is switched.
35 LED
operation
Traction control operation is
0 0 — Q — — Q —
turned on

10 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Machine monitor operation switch 1

1. Machine monitor mode selector switch 1


2. Machine monitor mode selector switch 2

WA200-6 11
SEN03258-00 10 Structure, function and maintenance standard

Setting of machine monitor

1. Spare rotary switch (SW1)


2. Spare rotary switch (SW2)
3. Spare rotary switch (SW3)
4. Spare dip switch (SW5-1)
5. Spare dip switch (SW5-2)
6. Spare dip switch (SW5-3)
7. Spare dip switch (SW5-4)
8. Spare dip switch (SW6-1)
9. Spare dip switch (SW6-2)
10. Spare dip switch (SW6-3)
11. Spare dip switch (SW6-4)

a It is prohibited to change setting of spare rotary switch and DIP switch.

Troubleshooting function
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.

12 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Character display function


q Machine monitor display and setting can be changed by using the character display.
q The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.

*1: When an ID entered from the "ID entry" screen is once approved, display changes directly to the "Select
function" screen without displaying the "ID entry" screen until the starting switch is turned "OFF".

WA200-6 13
SEN03258-00 10 Structure, function and maintenance standard

Operator mode functions 1


Self-check screen (0th layer)
q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON".
q During a self-check, entry through the machine monitor operating switch is not accepted.
q After ending the self-check, the self-check screen automatically moves to 1st layer.

Normal screen (1st layer)


q If the item of "13. RPM/SPEED" is set to "ADD" in the "Optional device selecting function" of machine
monitor, engine speed is displayed to the character display when the travel speed is displayed at the
center of the monitor.
q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the charac-
ter display.
q Pressing the "U" switch changes the screen to the 2nd layer.

1. Engine speed display


2. Travel speed display
A. In the case of "km/h" display
B. In the case "MPH" display

a When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character
display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in
"km/h".

14 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Failure code screen (1st layer)


q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code
screen.
q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item
of higher priority downward. If items have the same priority, the item that occurred most recently will be
displayed first.

Example of a failure code screen (simultaneously occurring errors: DX16KA, B@BCZK and CA431)

*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.

WA200-6 15
SEN03258-00 10 Structure, function and maintenance standard

Display of functions opened to the operator (2nd layer or below)


q Certain menus are not displayed unless the items in the "Optional device selecting function" of the
machine monitor are set.
q Pressing "U" switch allows selecting each menu.
q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not
pressed more than 60 seconds in the screen display of each menu.
q The language will be displayed as set in the Language selection function.
a See the "Operation and maintenance manual" for details of each menu.

*1: These menus are displayed when "ADD" is selected for "13. RPM/SPEED" item from the "Optional
device selecting function" of the machine monitor.
*2: These menus are displayed when "ADD" is selected for "12. RPM/OPT" item from the "Optional device
selecting function" of the machine monitor.

k It is prohibited to select "ADD" for "12. RPM/OPT" from the "Optional device selecting function"
of the machine monitor in the regions where the applicable law requires to display the travel
speed.

16 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Service mode functions 1


q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.

Procedure for switching to Service Mode


1. Checking of the screen display 3. ID input and confirmation
Check that the character display is set to the Operate the machine monitor mode selector
1st layer screen in the operator mode. switches 1 and 2 and enter ID. (ID: 6491)

2. Display of ID input initial screen


Pressing " u " switch and "<" switch simulta-
neously for 5 seconds or more displays the ID
entry initial screen.
a Pressing down the 2 switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the switches.

1) The cursor (C) is located at the highest-


order digit. Pressing "<" or ">" switch
changes the value of this digit in the range
of "0" to "9".
2) Press "U" switch at the target value to val-
idate it.
a The cursor moves to the 2nd digit
position.
3) Confirm the values for the 2nd digit and
onward following the same procedure.
a If you have entered a wrong value to
a p os it io n whe n the c ur s or was
located at any position other than the
highest-order digit, press " t" switch
to move the cursor to the highest-
order digit to enable to input correct
value. In this case, the values already
entered remain on the screen
unchanged.
a Pressing "t" switch when the cursor
is located at the highest-order digit,
the screen returns to the "1st layer" of
the operator mode.
a If switch is not operated more than 60
seconds on the "ID entry" screen, it
automatically returns to the "1st layer"
screen of the operator mode.
4) If ID is acknowledged upon confirming the
4th digit, the screen changes to the "Elec-
trical system failure history" selector
screen.

WA200-6 17
SEN03258-00 10 Structure, function and maintenance standard

Service mode menu

a Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same
menu.
a Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.

18 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Electrical system failure history display Real-time monitoring function (REAL-TIME


function (ELECTRIC FAULT) MONITOR)

a "**" field displays total number of the failure q This function is used to check on the input/out-
history currently recorded. (max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
a For the operating procedure of this function,
q The history is used to check on the electrical see "Special functions of machine monitor
system failures of each controller saved in the (EMMS)" in Testing and adjusting.
machine monitor. After repairing the failure
content and verifying normal function, the fail-
ure history may be erased.
a For the operating procedure of this function,
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.

Mechanical system failure history display Engine reduced-cylinder function (CYLINDER


function (MACHINE FAULT) CUT-OUT)

a "**" field displays total number of the failure q This function is used for the purpose of speci-
history currently recorded. (max. 20 histories to fying cylinder having defective combustion by
be stored) stopping fuel injection to each cylinder from the
fuel injector.
q The history is used to check on the mechanical a For the operating procedure of this function,
system failures of each controller saved in the see "Special functions of machine monitor
machine monitor. (EMMS)" in Testing and adjusting.
a For the operating procedure of this function,
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.

WA200-6 19
SEN03258-00 10 Structure, function and maintenance standard

No injection cranking function (NO INJECTION) Maintenance monitoring function (MAINTE-


NANCE MONITOR)

q Before restarting engine after a long-term stor-


ing of the machine, this function is used to q This function is used for changing the filter and
lubricate the engine internally. oil replacement timing and making ON/OFF
a For the operating procedure of this function, selection of this function.
see "Special functions of machine monitor a For the operating procedure of this function,
(EMMS)" in Testing and adjusting. see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.

Adjustment function (TUNING) Operating information display function


(OPERATION INFO)

q This function is used for correcting and adjust-


ing the installation errors and manufacturing q This function is used for displaying fuel con-
dispersion of the sensors, solenoid valves, etc. sumption per operating hour.
Function for changing control characteristics is a For the operating procedure of this function,
provided on user request. see "Special functions of machine monitor
These functions are also used when sensors, (EMMS)" in Testing and adjusting.
valves and controllers are replaced or added.
a For the operating procedure of this function,
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.

20 WA200-6
10 Structure, function and maintenance standard SEN03258-00

Optional device selecting function (OPTIONAL Model selection function (MACHINE)


SELECT)

q This function is used for displaying or changing


q This function is used for verifying the installed the setting of model information (machine
state of optional devices or when changing name).
their setting. a For the operating procedure of this function,
This function is also used for installing or see "Special functions of machine monitor
removing optional devices. (EMMS)" in Testing and adjusting.
a For the operating procedure of this function, a The figure shows when "WA250" is selected.
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.

Machine serial number input function Initialize function (INITIALIZE)


(MACHINE No. SET)

q This function is used to set the machine moni-


q This function is used for displaying or entering tor to the state set when delivered.
the serial number of machine. a Since this function is specially handled by the
Serial number of the set machine is used for factory, no modification is allowed.
controlling the machine.
a For the operating procedure of this function,
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.

WA200-6 21
SEN03258-00 10 Structure, function and maintenance standard

Input and output signals

AMP070-20P[CN-L24]
Pin No. Specifications I/O Group Form of use Signal name Remarks

1 (NC) — — — —

2 (NC) — — — —

3 (NC) — — — —
Constant power
4 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Constant power
5 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Power supply
6 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
Power supply
7 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
8 (NC) — — — —

9 GND I — GND GND

10 GND I — GND GND


D_OUT_3
11 O A D/O sink ECSS relay If equipped
(+24 V, sink 200 mA)
D_OUT_2
12 O A D/O sink Back-up lamp
(+24 V, sink 200 mA)
D_OUT_1
13 — — — —
(NC)
D_OUT_0
14 O A D/O sink Alarm buzzer
(+24 V, sink 200 mA)
15 (NC) — — — —

16 (NC) — — — —

17 GND I — GND GND

18 GND I — GND GND

19 GND I — GND GND

20 GND I — GND GND

22 WA200-6
10 Structure, function and maintenance standard SEN03258-00

AMP070-18P(1)[CN-L25]
Pin No. Specifications I/O Group Form of use Signal name Remarks
D_IN_0
1 I B D/I (+24 V) Head lamp
(24 V, 5 mA)
D_IN_2
2 I B D/I (+24 V) Starting switch C signal
(24 V, 5 mA)
3 (NC) — — — —
D_IN_6
4 I B D/I (+24 V) Quick coupler If equipped
(24 V, 5 mA)
D_IN_8
5 I B D/I (+24 V) ECSS switch If equipped
(24 V, 5 mA)
6 (NC) — — — —
D_IN_12
7 I C D/I (+24 V) Turn signal lamp, right
(NSW24 V, 5 mA)
D_IN_14
8 I C D/I (+24 V) U switch
(NSW24 V, 5 mA)
9 GND O — GND Signal GND
D_IN_1 Cooling fan automatic reverse
10 I B D/I (+24 V)
(24 V, 5 mA) rotation switch (manual)
11 (NC) — — — —

12 (NC) — — — —

13 (NC) — — — —
D_IN_9 Cooling fan automatic reverse
14 I B D/I (+24 V) If equipped
(24 V, 5 mA) rotation switch (automatic)
15 (NC) — — — —
D_IN_13
16 I C D/I (+24 V) Turn signal lamp, left
(NSW24 V, 5 mA)
D_IN_15
17 I C D/I (+24 V) t switch
(NSW24 V, 5 mA)
A_IN_0
18 I H A/I Alternator L signal
(0 – 30 V)

AMP070-12P(1)[CN-L26]
Pin No. Specifications I/O Group Form of use Signal name Remarks
D_IN_16
1 I D D/I (GND) Brake oil pressure
(24 V/GND, 5 mA)
2 (NC) — — — —
D_IN_20
3 I D D/I (GND) (air cleaner clogging)
(24 V/GND, 5 mA)
D_IN_22
4 I D D/I (GND) Traction control switch (S mode)
(24 V/GND, 5 mA)
D_IN_24
5 I E D/I (GND) HST oil filter clogging
(24 V/GND, 5 mA)
6 GND O — GND Sensor ground
D_IN_17
7 I D D/I (GND) (ECSS cut off switch)
(24 V/GND, 5 mA)
D_IN_19
8 I D D/I (GND) (service mode 2 and 3)
(24 V/GND, 5 mA)
D_IN_21
9 I D D/I (GND) (ECSS cutoff switch dummy)
(24 V/GND, 5 mA)
10 (NC) — — — —
D_IN_25
11 I E D/I (GND) (optional switch)
(24 V/GND, 5 mA)
A_IN_1
12 I H A/I Clearance lamp and tail lamp
(0 – 30 V)

WA200-6 23
SEN03258-00 10 Structure, function and maintenance standard

AMP070-18P(2)[CN-L27]
Pin No. Specifications I/O Group Form of use Signal name Remarks
D_IN_26
1 I E D/I (GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28 Parking brake left-unapplied
2 I E D/I (GND)
(24 V/GND, 5 mA) prevention
D_IN_30
3 I E D/I (GND) Normal emergency steering If equipped
(24 V/GND, 5 mA)

4 (NC) — — — —
D_IN_34
5 I F D/I (GND) Dimmer switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/I (GND) Parking brake dummy
(24 V/GND, 5 mA)
D_IN_38
7 I G D/I (GND) < switch
(24 V/GND, 5 mA)
8 (NC) — — — —

9 GND O — GND GND


D_IN_27
10 I E D/I (GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/I (GND) (engine oil level)
(24 V/GND, 5 mA)
12 (NC) — — — —

13 (NC) — — — —
D_IN_35 Parking brake left-unapplied
14 I F D/I (GND)
(24 V/GND, 5 mA) prevention dummy
D_IN_37
15 I G D/I (GND) > switch
(24 V/GND, 5 mA)
D_IN_39
16 I G D/I (GND) Operation of emergency steering If equipped
(24 V/GND, 5 mA)
17 (NC) — — — —

18 (NC) — — — —

AMP070-12P(2)[CN-L28]
Pin No. Specifications I/O Group Form of use Signal name Remarks
A_IN_2
1 I J A/I Fuel level sensor
(high-resistance input)
A_IN_4
2 I J A/I HST oil temperature sensor
(high-resistance input)
3 (NC) — — — —

4 (NC) — — — —

5 (NC) — — — —

6 GND O — GND GND


A_IN_3
7 I J A/I Brake oil temperature sensor
(high-resistance input)
8 (NC) — — — —

9 (NC) — — — —

10 (NC) — — — —

11 GND O — GND (GND)

12 (NC) — — — —

24 WA200-6
10 Structure, function and maintenance standard SEN03258-00

AMP070-12P(3)[CN-L29]
Pin No. Specifications I/O Group Form of use Signal name Remarks

1 (NC) — — — —

2 (NC) — — — —

3 CAN (+) I/O P CAN CAN (+)

4 (NC) — — — —

5 (NC) — — — —

6 GND O — GND GND

7 (NC) — — — —

8 CAN (–) I/O P CAN CAN (–)

9 (NC) — — — —

10 (NC) — — — —

11 (NC) — — — —

12 (NC) — — — —

AMP070-14P[CN-L30]
Pin No. Specifications I/O Group Form of use Signal name Remarks

1 (NC) — — — —

2 (NC) — — — —

3 (NC) — — — —

4 (NC) — — — —

5 (NC) — — — —

6 (NC) — — — —

7 (NC) — — — —

8 (NC) — — — —

9 (NC) — — — —

10 (NC) — — — —

11 (NC) — — — —

12 (NC) — — — —

13 (NC) — — — —

14 (NC) — — — —

WA200-6 25
SEN03258-00 10 Structure, function and maintenance standard

AMP040-8P
Pin No. Specifications I/O Group Form of use Signal name Remarks
Do not connect wiring
1 (NC) — — — —
harness on machine
Do not connect wiring
2 (NC) — — — —
harness on machine
Do not connect wiring
3 (NC) — — — —
harness on machine
Do not connect wiring
4 (NC) — — — —
harness on machine
Do not connect wiring
5 (NC) — — — —
harness on machine
Do not connect wiring
6 (NC) — — — —
harness on machine
Do not connect wiring
7 (NC) — — — —
harness on machine
Do not connect wiring
8 (NC) — — — —
harness on machine

Setting switches (On circuit board)


Switch
Specifications I/O Group Form of use Signal name Remarks
No.
1 16 Posi rotary switch 1 I — — (spare)

2 16 Posi rotary switch 2 I — — (spare)

3 16 Posi rotary switch 3 I — — (spare)

1 26 Posi DIP switch 1 I — — (spare)

2 26 Posi DIP switch 2 I — — (spare)


5
3 26 Posi DIP switch 3 I — — (spare)

4 26 Posi DIP switch 4 I — — (spare)

1 26 Posi DIP switch 5 I — — (spare)

2 26 Posi DIP switch 6 I — — (spare)


6
3 26 Posi DIP switch 7 I — — (spare)

4 26 Posi DIP switch 8 I — — (spare)

26 WA200-6
10 Structure, function and maintenance standard SEN03258-00

WA200-6 27
SEN03258-00

WA200-6 Wheel loader


Form No. SEN03258-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

28
SEN03259-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

10 Structure, function and


maintenance standard 1

Electrical system, Part 2


Electrical system (HST controller system) ...................................................................................................... 2
HST controller ............................................................................................................................................... 18
ECSS system................................................................................................................................................ 19
KOMTRAX system........................................................................................................................................ 20
Engine starting circuit.................................................................................................................................... 22
Engine stopping circuit.................................................................................................................................. 24
Preheating circuit .......................................................................................................................................... 25
Engine output derating function .................................................................................................................... 26
Automatic warm-up function ......................................................................................................................... 26
Parking brake circuit ..................................................................................................................................... 28
Max. traction switch ...................................................................................................................................... 30
Sensor........................................................................................................................................................... 31

WA200-6 1
SEN03259-00 10 Structure, function and maintenance standard

Electrical system (HST controller system) 1

a Except where otherwise specified, the displayed travel speed in this document represents the one when
17.5-25 tire is worn.

Input and output signals diagram


Travel speed range selector switch Ao o A HST motor 1 solenoid
Operating switch input

Variable shift control switch Ao o D HST motor 2 solenoid relay

Traction control switch Do o A Clutch solenoid

Solenoid output
Directional lever (F, N, R) Do o A Cooling fan motor flow rate control EPC valve

Parking brake lever intermediate switch Do o D Cooling fan motor reverse rotation solenoid relay

Parking brake lever bottom switch Do o D Directional solenoid (F, R)

Speed sensor A Po o D HST controller power holding relay


Sensor input

Speed sensor B Po o D HST safety relay

HST oil pressure sensor Ao o C Throttle upper limit (Eng_con)

Engine speed (Eng_con) Co o C Throttle lower limit (Eng_con)

Accelerator pedal angle (Eng_con) Co o C Automatic warm-up cancel (Eng_con)

Coolant temperature (Eng_con) Co


Monitor display information (Eng_con)
Boost temperature (Eng_con) Co o C (Failure code, real-time monitor, pilot lamp, alarm
buzzer, etc.)
HST controller

CAN output
Monitor display information (Eng_con)
(Failure code, real-time monitor, pilot lamp, alarm Co o C Travel speed (Mon)
buzzer, etc.)
o C ECSS operation command (Mon)

HST oil temperature (Mon) Co o C Back-up lamp operation command (Mon)

Cooling fan manual reverse rotation (Mon) Co o C Failure code signal (Mon)
CAN input

Cooling fan automatic reverse rotation (Mon) Co o C Real-time monitor signal (Mon)

ECSS (Mon) Co o C Pilot lamp signal (Mon)

Traction control S mode (Mon) Co o C Load frequency information (KOMTRAX)

Model selection (Mon) Co

Option device selecting (Mon) Co

Automatic fan switching cycle to reverse rotation


Co
(Mon)

Reverse rotation duration (Mon) Co

Traction control level (A, B, C) (Mon) Co

HST selector (A, B) (Mon) Co

Tire selection (Mon) Co

Service meter (Mon) Co

Eng_con: Engine controller


Mon: Machine monitor
KOMTRAX: KOMTRAX terminal

A: Analog signal
D: Digital signal
P: Pulse signal
C: CAN signal

2 WA200-6
10 Structure, function and maintenance standard SEN03259-00

HST controller gear shifting control function 1


Gear shifting function
q Receiving the travel speed range selector signal and the variable shift control signal, this function con-
trols HST motor 1, HST motor 2 and transfer clutch in such that the maximum travel speed suited for the
given state is produced.
Selected Variable shift control
Travel speed range Clutch solenoid HST motor 1 HST motor 2
speed signal input voltage
(km/h) output solenoid output solenoid output
range (V)
0 – 13
1st (depends on the variable ON MAX – MID Fixed to MAX (ON) 0.9 – 4.1
shift control signal)

2nd 0 – 13 ON MAX – MID Fixed to MAX (ON) —

3rd 0 – 18 ON, OFF MAX – 0 Fixed to MAX (ON) —

Fixed to MAX –
4th 0 – 38 ON, OFF MAX – 0 —
Variable (ON, OFF)

Relationship between accelerator pedal angle


and travel speed (A) for starting transfer clutch
switching modulation
Accelerator pedal angle (%)
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
8 km/h 8 – 10 km/h 10 km/h
Disengaged (C)
Disengaged o
7 km/h 7 – 9 km/h 9 km/h
Engaged (B)

Relationship between accelerator pedal angle


and travel speed (A) for switching HST motor 2
capacity
HST motor 2 Accelerator pedal angle (%)
capacity 0 – 65 65 – 90 90 – 100
Free (C) 8 km/h 8 – 10 km/h 10 km/h
Max. fixed (D) 9 km/h 9 – 11 km/h 11 km/h

WA200-6 3
SEN03259-00 10 Structure, function and maintenance standard

1. HST pump 5. Clutch solenoid valve


2. HST motor 1 6. HST motor 1 solenoid valve
3. HST motor 2 7. HST motor 2 solenoid valve
4. Transfer clutch 8. Transfer output shaft

Gear shifting display function


q The HST controller displays the state of input signals related to gear shift on the monitor by sending
them to the machine monitor via network.

1. Directional indicators
The directional lever position pilot lamps of the machine monitor indicate the state of the directional
lever based on the input data to the HST controller.
When the directional lever is at the neutral position and no input signal is sent to the HST controller, all
the directional lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the HST controller by accident, two directional lever position
pilot lamps of the machine monitor may turn on at the same time.
As the directional lever is set to "R (reverse)" the HST controller activates the backup lamp relay to light
the reverse lamp and sound the back-up alarm.

2. Speed range indicator


The travel speed range selector switch position pilot lamp of the machine monitor displays the state of
the travel speed range selector switch being sent to the HST controller.

Variable shift control system


q When the travel speed range selector switch is set to the 1st speed, the variable shift control signal
allows adjusting the maximum speed in the range of 4 - 13 km.

4 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Transfer clutch control function


q In order to reduce impacts resulting from connecting the transfer clutch or to prevent inadequate torque
due to delayed connection of the transfer clutch, this function adjusts the clutch oil pressure to an opti-
mum level for the machine state (travel speed, travel load, HST oil temperature, directional lever and
accelerator opening ratio) by referencing the modulation table of the HST controller.
q In order to reduce lack of the torque, this function maintains the modulation control when the clutch is
released.

Traction control function


q Receiving the traction control signal, this function derates the maximum capacity of HST motor 1 to con-
trol the traction force.
q "Traction level selecting function" of the machine monitor allows selecting a desired traction force out of
3 levels (A, B and C).
q The traction control operation pilot lamp remains turned on as long as the traction control operation is
continued.
a For the operating method of this function, see the "Operation and maintenance manual".

S mode function
q Receiving the S mode signal, this function reduces the maximum capacity of HST motor 1 and the upper
limit of the throttle opening ratio in order to secure an optimum drive force for the dozing work on very
slippery road surface (on the snow-covered road, sandy terrain, etc.).
q This function restricts sudden start in forward travel by reducing skidding of tires through control of the
drive force. And by securing smooth start of the machine, this function offers enhanced operating perfor-
mance.
q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode opera-
tion is continued.
a The traction force control in the S mode is enabled when the directional lever is set to the "forward" posi-
tion and the machine is traveling forward or stopped.
a For the operating method of this function, see the "Operation and maintenance manual".

Features
Switch
Pilot lamp Traction level Road Guideline
position Traction Material
condition
1
OFF 1
(OFF)
Suitable for loading work. Improves work
Powerful Hard-packed Un-slippery efficiency and provides antislip by selecting
2A
I I I traction level depending on material and road
O O O conditions.
2 2
2B Soft Loose Slippery
(ON) (ON)
Select when operating with the special
2C
attachment which requires small traction force.
Provides the best driving force on very
Select when the machine tends to slip when
3 3 slippery road surfaces covered by snow,
3 forwarding, such as on snow or sand covered
(S mode) (ON) sand, etc. Prevents the tires from slipping to
road surface.
facilitate work.

WA200-6 5
SEN03259-00 10 Structure, function and maintenance standard

The maximum traction force available when the


travel speed range selector switch is set to
"1st" and the traction control switch is set to
"ON"

q When the travel speed range selector switch


(1) is set to "1st" and the variable shift control
switch (2) is turned fully to the left, setting the
traction control switch to the ON position does
not reduce the maximum traction force. In this
case, the maximum traction force remains at
the same level as when the traction control
switch is set to the "OFF" position.
q As clockwise turning of the variable shift con-
trol switch (2) is continued, the traction force
approaches the maximum traction force being
set from the "Traction level selecting function"
of the machine monitor.
q It is possible to obtain the maximum traction
force, which has been set from the traction
control switch and "Traction level selecting
function" of the machine monitor, by turning the
variable shift control switch (2) fully to the right.

6 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Max. traction function


q Pressing the max. traction switch while the traction control is "ON" or the S mode is selected cancels the
traction control or the S mode temporarily to increase the maximum drawbar pull.
q If the directional lever or directional selector switch is operated, or the max. traction switch is pressed
again while the traction control or S mode is cancelled from the max. traction switch, the traction "ON"
state or S mode is restored.
q As long as the traction control or S mode is cancelled from the max. traction switch, the traction control
operation pilot lamp or S mode operation pilot lamp of the machine monitor remains turned off.
a Holding down the max. traction switch for a second or longer cancels the traction control or S mode as
long as it is held down. The traction control or S mode is restored at the moment the switch is released.
a If the traction control is sequentially turned "ON" and "OFF" in less than a second, the traction control or
S mode is cancelled temporarily just like the max. traction switch is held down for less than a second.

1. Traction control switch


2. Max. traction switch
3. HST controller
4. Machine monitor

a. Traction control switch signal


b. S mode signal
c. CAN signal

WA200-6 7
SEN03259-00 10 Structure, function and maintenance standard

HST controller protection function 1

HST motor 1 overrun prevention function 1


q If the 1st or 2nd speed is selected while the machine is traveling at a high speed with the travel speed
range selector switch being set to the 3rd or 4th, the transfer clutch is engaged during the high speed
travel, preventing HST motor 1 to overrun beyond the allowable rotating speed.
q In order to prevent the overrun, this function disables the gear shift from the 3rd or 4th to the 2nd or 1st
when the transfer clutch is released.
q As above gear shift is disabled, this function generates "OVERRUN PROTECT" message on the
machine monitor character display and activates the alarm buzzer.
q This error status is reset as the transfer clutch is engaged or the travel speed range selector switch is
set to an allowable gear shift position.
a Above error message is not sent to KOMTRAX terminal.
Gear shift operation Behavior after gear shift
Switch position Switch Actual speed
State of transfer Display of
before gear position after range after Remarks
clutch after gear shift message
shift gear shift gear shift
2nd 2nd
Gear shift available independent
1st Connected 3rd 3rd Not displayed
of traveling speed
4th 4th
1st 1st
Gear shift available independent
2nd Connected 3rd 3rd Not displayed
of traveling speed
4th 4th
1st 1st
Connected 2nd 2nd Not displayed
4th 4th Gear shift to 1st or 2nd becomes
3rd available only when the clutch is
(*1) 1st 3rd engaged.
Displayed
Other than the 2nd 3rd
connected state 4th 4th Not displayed
1st 1st
Connected 2nd 2nd Not displayed
3rd 3rd Gear shift to 1st or 2nd becomes
4th available only when the clutch is
(*1) 1st 3rd engaged.
Displayed
Other than the 2nd 3rd
connected state 3rd 3rd Not displayed
*1: The clutch is released including the ongoing clutch connection modulation (*2) and clutch release modulation state.
*2: It indicates the period 1.2 seconds after the clutch connection modulation has been started while the machine is
traveling at 7 up to 9 km/h.

Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switch-
ing modulation
Accelerator pedal angle (%)
Transfer clutch
0 – 65 65 – 90 90 – 100
Engaged o
8 km/h 8 – 10 km/h 10 km/h
Disengaged (B)
Disengaged o
7 km/h 7 – 9 km/h 9 km/h
Engaged (C)

8 WA200-6
10 Structure, function and maintenance standard SEN03259-00

HST motor 1 overrun prevention function 2


q Downhill travel at 1st or 2nd gear speed tends to allow the machine to increase the travel speed. This
function prevents the rotational speed of HST motor 1 goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function controls the HST motor 1 capacity to the allowable max-
imum if the travel speed goes beyond 14 km/h.

Travel speed control function


q Downhill travel at a high speed tends to allow the machine to exceed the speed limit because the rota-
tional speed of HST motor 2, axle and engine goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function fixes the HST motor 2 capacity to the allowable maxi-
mum if the travel speed goes beyond 36 km/h.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the
machine monitor character display and activates the alarm buzzer.
q This error state is reset as the travel speed goes below 35.6 km/h or less.
a Above error message is not sent to KOMTRAX terminal.

Engine overrun prevention function


q If the HST motor 2 capacity reaches its allowable rotating speed when the machine travels downhill at a
high speed, the HST pump and engine rotation becomes high speed. This function prevents the HST
motor 2 to overrun beyond the allowable rotating speed.
q This function prevents the HST motor 2 solenoid valve to be set to "ON" (fixed to MAX) when the travel
speed is more than 30 km/h and the engine speed is more than 2,925 rpm. If the HST motor 2 solenoid
valve is already set to "ON", the solenoid valve is forcibly set to "OFF" to prevent the HST pump and
engine from overrun.
q This function is canceled when the engine speed goes below 2,825 rpm.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the
machine monitor character display and activates the alarm buzzer.

Neutralizer function
q When the parking brake lever is pulled (the switch at the bottom of the parking brake lever is "OFF"), this
function, independent of the directional lever position, holds HST pump at the neutral in order to prevent
dragging of the parking brake.

WA200-6 9
SEN03259-00 10 Structure, function and maintenance standard

Economy operation pilot lamp function 1


q In order to prompt the operator for the low fuel consumption operation, this function lights up the econ-
omy operation pilot lamp as long as the low fuel consumption operation is continued.
q The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at
less than 75% for 0.5 seconds or longer.
q The economy operation pilot lamp can be constantly turned off by selecting "NO ADD" for "4. ECO
LAMP" item from the "Optional device selecting function" of the machine monitor.
a For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.

10 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Cooling fan control function 1

1. HST controller Input and output signals


2. Machine monitor HST controller
3. Engine controller a. CAN signal
4. Cooling fan pump b. Cooling fan motor flow rate control signal
5. Cooling fan motor c. Cooling fan reverse signal
5a. Cooling fan motor flow rate control EPC valve
5b. Cooling fan reverse solenoid valve Machine monitor
6. Cooling fan reverse switch d. Cooling fan automatic reverse signal
7. Machine monitor mode selector switch 1 e. Cooling fan manual reverse signal
8. Machine monitor mode selector switch 2 f. CAN signal
9. Cooling fan reverse solenoid valve relay g. "U" switch signal
10. HST oil temperature sensor h. "t" switch signal
11. Boost pressure and oil temperature sensor i. ">" switch signal
12. Coolant temperature sensor j. "<" switch signal
13. Engine speed sensor k. HST oil temperature signal
14. Engine
15. Radiator Engine controller
l. CAN signal
m. Boost pressure and temperature signal
n. Engine speed signal
o. Coolant temperature signal

WA200-6 11
SEN03259-00 10 Structure, function and maintenance standard

Fan control
q Employment of the hydraulically driven cooling fan and the control of the flow rate of the hydraulic motor
allow reducing the horsepower loss and noises as well as cutting the warm-up operation time in a low
temperature environment.
q Engine speed, coolant temperature and boost air temperature received by the engine controller, and the
information of HST oil temperature received by the machine monitor are sent to the HST controller via
the network.
q Based on the received information, the HST controller sends the signal current to the cooling fan motor
flow rate control EPC valve in order to set the fan speed to a level suitable for the respective tempera-
ture levels and the engine speed.

Fan speed in accordance with temperature

*1: The target fan speed is determined based on the coolant temperature, HST oil temperature or boost air
temperature data, whichever is the highest.
*2: Within this range, the fan speed is set according to the coolant temperature, HST oil temperature and
boost air temperature.
*3: When the boost air temperature is at the lower limit or when the HST oil temperature is low, the fan
speed is decreased to increase the oil and coolant temperature (heater spurting out temperature) and
cut the warm-up operation time.
(the fan speed in this area is controlled based on the hysteresis of each temperature.)

12 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Control at start of engine


q In order to protect the fan from being stopped by low oil temperature or settled snow or dusts, the fan
speed is temporarily increased immediately after the engine is started to aid start of the fan rotation.
q After the basic control is turned on, normal fan control is carried on based on the procedure described in
the section of "Fan speed in accordance with temperature".
a The fan control (derating of the minimum fan speed) at start of the engine is conducted only once after
the starting switch has been set to "ON". When, however, the starting switch was turned "OFF" once
and then turned "ON" again, the control is implemented one more time if the control starting conditions
are met.

The control (derating of the minimum fan speed) at start of engine is carried out if every condition in the fol-
lowing table is met.

Condition 1 Starting switch is turned "ON".

Condition 2 Engine speed is 700 rpm or above.

Engine is rotating forward.


Condition 3 [above, however, does not apply as a condition if the controller recognized that switching in the rotating
direction is taking place.]

Condition 4 After the starting switch is turned "ON", the control at start of engine has not been carried out yet.

*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air
temperature is 20°C or above.

Point A: Starting switch is turned "ON" (when engine is stopped)


Point B: Control starting conditions are met
Area C: Minimum fan speed is restricted
Area D: Basic control is turned on

WA200-6 13
SEN03259-00 10 Structure, function and maintenance standard

Fan reverse rotation function


q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation solenoid valve of the cooling fan motor is activated, reverse rotating the fan.

1. Fan manual reverse rotation function


The operator can select the desired fan rotation direction by pressing the fan reverse rotation switch to
"MANUAL" for 0.5 seconds or longer.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is
reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on
blinking until the preparation for switching is completed.
As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restrict-
ing signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the
switching is underway. Above control, however, is not applicable when the HST oil temperature is 30°C
or above.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is con-
tinued.

The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.

Condition 1 The fan reverse rotation switch was set to "MANUAL" for 0.5 seconds or longer.

Condition 2 Engine speed over 500 rpm and below 1,200 rpm.
(*1) [above is required to prevent generation of peak pressure in the process of switching the direction.]
Coolant temperature is below 90°C.
Condition 3
[above is required to prevent overheating.]
HST oil temperature is below 95°C.
Condition 4
[above is required to prevent overheating.]
Boost air temperature is below 70°C.
Condition 5
[above is required to prevent overheating.]
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
Condition 6 500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]

The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1 While the fan is rotating reverse, the fan reverse switch was again set to "MANUAL" and the engine
(*1) speed went to below 1,200 rpm.
Condition 2 After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than
(*1) 1,200 rpm.

Condition 3 The engine has stopped.

*1: The engine speed-related requirement (1,200 rpm) is exempted when the HST oil temperature is
30°C or above.

2. Overheat prevention function


If overheat in the coolant temperature, HST oil temperature or boost air temperature was recognized
while the fan was rotating reverse, the reverse rotation is forcibly stopped and the forward rotation is
turned on in order to increase the air flow to the radiator.

3. Fan speed during reverse rotation


While the reverse fan rotation is continued, this function sets the fan speed to the maximum by cutting
off the command current (sets the command current to 0 mA) to the fan motor flow rate control EPC
valve.
Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the
cleaning work easier.

14 WA200-6
10 Structure, function and maintenance standard SEN03259-00

4. Fan automatic reverse rotation function


(if equipped)
Setting the fan reverse rotation switch to "AUTO" allows changing the fan rotation direction switching
cycle and the reverse rotation duration at a specific interval.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is
reversed responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on
blinking until the preparation for switching is completed.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is con-
tinued.

The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.

Condition 1 The fan reverse rotation switch is set to "AUTO".

Coolant temperature is below 90°C.


Condition 2
[above is required to prevent overheating.]
HST oil temperature over 30°C and below 95°C.
Condition 3
[the upper limit of 95°C is required to prevent overheating.]
Boost air temperature is below 70°C.
Condition 4
[above is required to prevent overheating.]
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
Condition 5 500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]

Condition 6 The fan rotation direction switching cycle or the specified reverse rotation duration has elapsed.

The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
After the fan reverse rotation switch has been set to any position other than "AUTO" during the
Condition 1
reverse fan rotation, the HST oil temperature reached 30°C or above.
After the fan rotation direction switching cycle or the specified reverse rotation duration has elapsed,
Condition 2
the HST oil temperature reached 30°C or above.

Condition 3 The engine has stopped.

5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
(if equipped)
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items "Adjustment of interval of fan automatic reverse
operation" and "Adjustment of continuance of fan automatic reverse operation" with the adjusting func-
tion of the machine monitor.
a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and
adjusting.

WA200-6 15
SEN03259-00 10 Structure, function and maintenance standard

System circuit diagram 1

a Items marked with "*1" in drawing may or may not installed.

16 WA200-6
10 Structure, function and maintenance standard SEN03259-00

WA200-6 17
SEN03259-00 10 Structure, function and maintenance standard

HST controller 1

Input and output signals

DEUTSCH-40P [CN-HST]
Pin Input/Output Pin Input/Output
Signal name Signal name
No. signal No. signal
1 VB (controller power) Input 21 GND (controller GND) —
2 Starting switch ACC signal Input 22 HST sensor power 5V Input
3 Wake up Input 23 Travel speed adjusting dial Input
4 Directional selector switch F Input 24 Directional selector switch R Input
5 Directional lever N Input 25 Directional selector switch operating switch Input
6 Parking brake lever intermediate switch Input 26 Speed sensor A Input
7 HST controller power holding relay Output 27 HST motor 2 solenoid relay Output
8 NC — 28 CAN0_H Input/Output
9 Clutch solenoid Output 29 Cooling fan motor flow rate control EPC Output
10 HST pump F solenoid Output 30 VIS (solenoid power) Input
11 VB (controller power) Input 31 GND (controller GND) —
12 Starting switch ACC signal Input 32 GND (sensor GND) —
13 Alternator L signal Input 33 HST oil pressure sensor Input
14 Directional selector switch N Input 34 Directional lever F Input
15 Directional lever R Input 35 Traction control switch Input
16 Parking brake lever bottom switch Input 36 Speed sensor B Input
17 HST safety relay Output 37 Cooling fan motor reverse rotation solenoid relay Output
18 NC — 38 CAN0_L Input/Output
19 HST motor 1 solenoid Output 39 Travel speed range selector switch Input
20 HST pump R solenoid Output 40 SOL_COM (solenoid common GND) —

18 WA200-6
10 Structure, function and maintenance standard SEN03259-00

ECSS system 1

(if equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System

1. HST controller Operation


2. Machine monitor q The operating condition of ECSS is as follows.
3. ECSS switch
ECSS operation
4. ECSS relay ECSS switch Travel speed [km/h]
signal
5. ECSS solenoid valve
OFF 0 – Max.
6. Speed sensor OFF
(*2) Max. 4
ON
Input and output signals (*1) Min. 5 ON

HST controller
a. Travel speed signal A
b. Travel speed signal B
c. CAN signal

Machine monitor
d. CAN signal
e. ECSS switch "ON" signal
f. ECSS operation signal

Outline
q When the machine travels at high speed, the
damping effect of the accumulator charged
with high-pressure gas and the automatic con-
trol of the lift cylinder circuit relief pressure ECSS switching point A B
under each travel condition damp the vertical
movement of the work equipment and reduce (*2) (*1)
Travel speed [km/h]
rocking of the chassis. As a result, the operator 4 5
comfort is improved, spillage of material is pre-
*1. It is allowed to select any travel speed at the
vented, and the working efficiency is improved.
ECSS switching point (B) in the range of 5 to 8
km/h by adjusting the items "Adjustment of
Setting method
ECSS operation travel speed" with the adjust-
q The ECSS can be enabled only when "ADD" is ing function of the machine monitor.
selected for "5. E.C.S.S." item from the *2. The travel speed available at ECSS switching
"Optional device selecting function" of the point (A) is obtained by deducting 1 km/h from
machine monitor. that available at the switching point (B)
a For the setting procedure, see "Special func- (namely, 4 - 7 km/h).
tions of machine monitor (EMMS)" in Testing a For the adjustment procedure, see "Special
and adjusting. functions of machine monitor (EMMS)" in Test-
ing and adjusting.

WA200-6 19
SEN03259-00 10 Structure, function and maintenance standard

KOMTRAX system 1

(if equipped)

q KOMTRAX terminal transmits various machine information by use of the radio communication. The
KOMTRAX operator is allowed to reference these information in the office and offer them to the cus-
tomer through various services.

a When offering the information to the customer, it is required to separately implement the KOMTRAX
system station opening procedure.

The information transmitted from the KOMTRAX terminal includes the following.
1. Traveling map
2. Service meter
3. Position information
4. Error history

20 WA200-6
10 Structure, function and maintenance standard SEN03259-00

KOMTRAX terminal 1

1. Communication antenna connector


2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

Input and output signals


DEUTSCH-40P [CN-L80]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN0_L Input/Output 27 Starting switch C signal Input
8 CAN0_H Input/Output 28 Alternator L signal Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch ACC signal Input
17 NC — 37 Power supply GND —
18 NC — 38 Power supply GND —
19 NC — 39 Constant power supply (24 V) Input
20 Immobilize signal Output 40 Constant power supply (24 V) Input

Outline
q The KOMTRAX terminal can send information
via wireless communication antenna, acquiring
various information of the machine from the
network signal in the machine and the input
signal. Also, the terminal incorporates CPU
(Central Processing Unit) and provide the wire-
less communication function and the GPS
(Global Positioning System) function.
q There are the LED lamp and the 7-segment
indicator lamp in the display area, and these
lamps are used for the testing and the trouble-
shooting.

WA200-6 21
SEN03259-00 10 Structure, function and maintenance standard

Engine starting circuit 1

1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Slow-blow fuse secure safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the
5. Fuse box 2 directional lever is at any position other
6. Starting switch than N (neutral).
7. Directional lever
8. Neutral safety relay 2. The KOMTRAX engine cut-out circuit is
9. KOMTRAX engine cut-out relay (if equipped) employed to disable the engine from starting
10. HST controller power holding relay when the KOMTRAX terminal receives an
11. Starting motor safety relay engine cut command issued through external
12. Starting motor operation.
13. Alternator (if equipped)
14. HST controller
15. Engine controller
16. Machine monitor
17. KOMTRAX terminal (if equipped)
18. Engine controller cut-out relay
19. CAN resistor

22 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Operation
1. When starting switch is turned "ON"
q As the starting switch is turned "ON", ter-
minals B and BR of the starting switch are
closed and the current flows from the bat-
tery through the starting switch and bat-
tery relay coil to the ground, thereby
closing the contact of the battery relay. As
a result, the power is supplied to each cir-
cuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.

2. Neutral safety circuit


q Setting the directional lever to "N (neu-
tral)" conducts the current from contact N
of the directional lever to the neutral safety
relay to activate it.

3. When starting switch is set to "START"


q As the starting switch is set to "START",
the current flows through the starting
switch terminal C, KOMTRAX engine cut-
out relay and neutral safety relay to the
starting motor safety relay to start the
engine.
q When the directional lever is set to any
position other than "N (neutral)", the neu-
tral safety relay is not activated and inter-
rupts the engine startup.
q As KOMTRAX terminal receives the exter-
nally applied engine cut-out command,
KOMTRAX engine cut-out relay is acti-
vated, shutting down the circuit from the
starting switch terminal C to the starting
motor safety relay. Thus, engine start-up
becomes unavailable.
(if equipped)

WA200-6 23
SEN03259-00 10 Structure, function and maintenance standard

Engine stopping circuit 1

Operation
q Setting the starting switch to "OFF" cuts off
ACC signal from the starting switch terminal
ACC to the engine controller.
q Although ACC is cut off, the engine controller
keeps the engine controller cut-out relay work-
ing to maintain the current flow to the engine
controller until its internal processing is com-
plete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation, stopping supply
of the voltage from the alternator terminal L.
And the current from the starting switch termi-
nal BR is also stopped and the contacts of the
battery relay are opened. Consequently, the
power supplied to each circuit of the machine
is stopped.

24 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Preheating circuit 1

1. Battery Operation
2. Battery relay q Set the starting switch to "ON" to start the
3. Slow-blow fuse engine controller. At this time, if intake air tem-
4. Fuse box 1 perature is -4°C or below, the engine controller
5. Starting switch starts up the electrical intake air heater imme-
6. Engine controller diately after the starting switch is turned "ON"
7. Machine monitor to initiate preheating by the electrical intake air
8. Electrical intake air heater relay heater.
9. Electrical intake air heater q The preheating time is set as shown below.
10. Boost pressure and temperature sensor

Outline
q The automatic preheating system is installed
so that the engine will start easily in a cold dis-
trict.
q The automatic preheating system is capable of
cutting the preheating time short as the starting
switch is set to "ON". This system is also capa-
ble of automatically setting the preheating
duration referencing temperature of intake air.
q Setting the starting switch to "ON" lights the
preheater pilot lamp of the machine monitor
and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating dura-
tion referencing the intake air temperature
being sent from the boost pressure sensor and
temperature sensor.
q The pilot lamp remains turned on as long as
preheating is continued. Keep the starting
switch in the "ON" position during this time.
Setting the starting switch to "START" from this
state resets preheating.

WA200-6 25
SEN03259-00 10 Structure, function and maintenance standard

Engine output derating function 1 Automatic warm-up function 1

q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque function warms it up by increasing the engine
or speed. low idle speed.
q If the coolant temperature is below 20°C at
q Following figure shows the engine torque per- starting of the engine, this function increases
formance when the torque was derated. the low idle speed to 1,000 rpm, and to 900
rpm in the range from 20°C to 40°C. The con-
ditions required for increasing the low idle
speed depend on the coolant temperature as
shown in the figure below.
q If the coolant temperature reaches 30°C or
above, the low idle speed decreases to 900
rpm. If it reaches 50°C or above, it returns to
825 rpm.

A: Derated to approximately 30% of the maximum


torque point
B: Derated to approximately 50% of the rated out-
put point

q Following figure shows the engine torque per-


formance when the engine speed was derated.

The automatic warm-up function is reset and the


engine speed returns to 825 rpm as any of the fol-
lowing conditions is met.
The coolant temperature reaches 50°C or
Condition 1 above while the automatic warm-up
function is enabled.
The accelerator pedal angle remains at
Condition 2
100% for 30 seconds or more.
The automatic warm-up function remains
Condition 3
being enabled for 50 minutes or more.
The directional lever or directional
selector switch is set to "Forward" or
"Reverse" while the automatic warm-up
function is enabled.
A: Derated near to the engine speed at maximum Condition 4
(When the directional lever and
torque point directional selector switch are returned to
"Neutral" to stop the machine, the
automatic warm-up function restarts.)

26 WA200-6
10 Structure, function and maintenance standard SEN03259-00

WA200-6 27
SEN03259-00 10 Structure, function and maintenance standard

Parking brake circuit 1

1. Parking brake lever intermediate switch


2. Parking brake lever bottom switch
3. HST controller
4. Machine monitor
5. Alarm buzzer
6. HST controller power holding relay
7. HST safety relay
8. Clutch solenoid valve
9. HST motor 1 solenoid valve
10. HST pump forward solenoid valve
11. HST pump reverse solenoid valve

28 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Operation
Starting switch position OFF ON

State of engine Stopped Running

Parking brake lever area Free Mid Lock Free Mid Lock Free Mid Lock
Parking brake lever Close Open Close Open Close Open
intermediate switch (1)
Parking brake lever
bottom switch (2) Close Open Close Open Close Open
[for parking brake pilot
lamp operation]
Parking brake reminder [*1], [*2] OFF [*1] OFF OFF
caution lamp ON (Reset) ON (Reset) (Reset)
(Alarm buzzer) (Sounded) (Sounded)
Parking brake pilot lamp OFF OFF ON OFF ON

When the parking brake lever is set to "Mid"


position
q When the parking brake lever is set to the mid
position, the bottom switch (2) is open but
intermediate switch (1) is closed.
q The parking brake pilot lamp comes on only
when the starting switch is "ON".
q As bottom switch (2) opens, the output to the
forward and reverse solenoid valves of HST
pump is stopped to prevent dragging of the
parking brake. And, at the same time, the
directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
When the parking brake lever is set to "Free" *1: When the starting switch is turned from "ON" to
position "OFF":
q When the parking brake lever is set to the free q The parking brake reminder caution lamp turns
position, the intermediate switch (1) and bot- on and the alarm buzzer sounds.
tom switch (2) are both closed. q The HST controller power holding relay
q The parking brake pilot lamp goes off indepen- remains turned on, conducting current to the
dent of the given state. HST controller and maintaining the HST motor
q The parking brake is released. 1 solenoid valve and clutch solenoid valve
*1: When the starting switch is turned from "ON" to being activated. Thus, the machine is pro-
"OFF": tected from slipping through a slope.
q The parking brake reminder caution lamp turns
on and the alarm buzzer sounds. When the parking brake lever is set to "Lock"
q The HST controller power holding relay position
remains turned on, conducting current to the q Pulling the parking brake lever fully opens both
HST controller and maintaining the HST motor the intermediate switch (1) and bottom switch
1 solenoid valve and clutch solenoid valve (2).
being activated. Thus, the machine is pro- q The parking brake pilot lamp comes on only
tected from slipping through a slope. when the starting switch is "ON".
*2: If the parking brake lever is set to any position q The parking brake reminder caution lamp goes
other than "Lock" when the starting switch is at off independent of the given state.
"OFF", the parking brake reminder caution q As bottom switch (2) opens, the output to the
lamp remains turned off and the alarm buzzer forward and reverse solenoid valves of HST
is also not activated. And HST motor 1 sole- pump is stopped to prevent dragging of the
noid valve and clutch solenoid valve remain parking brake. And, at the same time, the
inactivated. directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
q The parking brake is activated.

WA200-6 29
SEN03259-00 10 Structure, function and maintenance standard

Max. traction switch 1

1. Switch A Function
Mono-lever type : green wiring harness q These switches are installed on the knob of the
2-lever type : white wiring harness work equipment (lift arm) control lever. Switch
2. Switch B A (1) functions as the max. traction switch and
Mono-lever type : white wiring harness switch B (2) functions as an optional switch
2-lever type : yellow wiring harness [reserved].
3. Wiring harness q Both of switch A (1) and switch B (2) are of
momentary type, that is, their contacts are
closed only while they are pressed.

30 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Sensor 1

Speed sensor

1. Hall IC 5. Heat shrink tube


2. Circuit board 6. Protective tube
3. O-ring 7. Lead wire
4. Housing 8. Connector

Function
q The speed sensor is installed on the transfer case. It generates two different types of pulses depending
on the rotational direction and speed of the gear.

WA200-6 31
SEN03259-00 10 Structure, function and maintenance standard

HST oil temperature sensor


Brake oil temperature sensor

1. Connector 2. Plug 3. Thermistor

Function
q The HST oil temperature sensor and the brake oil temperature sensor are installed on the motor 2
hydraulic piping and front axle, respectively. They generate the signal for the change in temperature as
variation in the resistance of the thermistor.

HST oil pressure sensor

1. Sensor 2. Lead wire 3. Connector

Function
q The HST oil pressure sensor is installed on the motor 2 solenoid block to measure the oil pressure in the
HST circuit and generate the corresponding signal.

32 WA200-6
10 Structure, function and maintenance standard SEN03259-00

HST oil filter clogging sensor

1. Terminal 2. Plug

Function
q This sensor is installed on the HST oil filter to monitor the oil pressure before and after the filter. If the
pressure goes beyond the specified level, the switch is set to "ON".

Coolant level sensor

1. Float 3. Connector
2. Sensor 4. Sub-tank

Function
q This sensor is installed in the bulkhead. As the coolant goes below the specified level, the float moves
down, and the switch is set to "OFF".

WA200-6 33
SEN03259-00 10 Structure, function and maintenance standard

Fuel level sensor

1. Connector 4. Body 7. Spacer


2. Float 5. Spring
3. Arm 6. Contact

Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.

34 WA200-6
10 Structure, function and maintenance standard SEN03259-00

Accelerator pedal sensor

1. Pedal Output characteristics


2. Connector
3. Sensor

Function
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pedal pressing angle.

Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.

Idle validation signal


q The sensor detects the accelerator pedal oper-
ation. As the accelerator pedal is released, it
outputs the signal being entered to No. 5 pin
from No. 4 pin. And as the accelerator pedal is
pressed, it outputs the signal being entered to
No. 6 pin from No. 4 pin.

WA200-6 35
SEN03259-00 10 Structure, function and maintenance standard

Water-in-fuel sensor

1. Connector 3. Sensor
2. Tube 4. O-ring

Function
q This sensor is installed in the cup of the fuel pre-filter. It outputs the signal as entrainment of water in fuel
is sensed.

Boom kick-out proximity switch


(if equipped)
Bucket positioner proximity switch

1. Switch 3. Operation indication lamp


2. Locknut 4. Connector

Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame.
And the bucket positioner proximity switch is installed on the bucket cylinder. As long as the plate is
positioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".

36 WA200-6
10 Structure, function and maintenance standard SEN03259-00

WA200-6 37
SEN03259-00

WA200-6 Wheel loader


Form No. SEN03259-00

©2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

38
SEN03731-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

20 Standard value table 1


Standard service value table
Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3

WA200-6 1
SEN03731-00 20 Standard value table

Standard service value table 1


Standard service value table for engine 1

Machine model WA200-6


Engine SAA4D107E-1
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle (*) 2,225 (+70/-50) 2,225 (+70/-50)
Engine speed rpm
Low idle (*) 825 (+25/-50) 825 (+25/-50)
Exhaust temperature
All revolution ranges
(Turbocharger outlet tem- °C Max. 700 750
(Atmospheric temperature: 20°C)
perature)
Intake air pressure • At rated output kPa Min. 133 107
(Boost pressure) • At aftercooler outlet side {mmHg} {Min. 1,000} {800}

Engine coolant tempera- At rated output Pollution Max. 12 22


Exhaust gas color
ture: Within operating range At sudden acceleration level % Max. 25 35
Intake valve 0.25 ± 0.05 0.152 – 0.382
Valve clearance Normal temperature mm
Exhaust valve 0.51 ± 0.05 0.381 – 0.763
• At rated output
kPa Max. 0.98 1.96
Blow-by pressure • Engine coolant temperature: Within operating
{mmH2O} {Max. 100} {200}
range
At high idle
SAE0W30E0S Min. 0.29 0.25
Engine coolant tempera-
{Min. 3.0} {2.5}
ture: Within operating range SAE0W40E0S MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.10 0.07
Engine coolant tempera- SAE30DH {Min. 1.0} {0.7}
ture: Within operating range
Oil temperature All engine speed ranges (Inside oil pan) °C 80 – 110 Min. 120
Deflection under finger pres-
Idler pulley –
sure of approx. 58.8 N Auto-tensioner Auto-tensioner
crankshaft pulley
{approx. 6 kg}
Belt tension mm
Deflection under finger Air conditioner com-
pressure of approx. 98 N pressor – crankshaft 8 – 11 8 – 11
{approx. 10 kg} pulley

*: Value when mounted on machine (Different from value in Engine Shop Manual)

2 WA200-6
20 Standard value table SEN03731-00

Standard service value table for chassis 1

Machine model WA200-6


Category

Standard value Service limit


Item Measurement conditions Unit
for new machine value

5.9 (+5.9/0)
N–
13.7 {1.4}
FORWARD {0.6 (+0.6/0)}
Operating N
Directional lever

effort {kg}
5.9 (+5.9/0)
N– • Engine stopped 13.7 {1.4}
REVERSE {0.6 (+0.6/0)}
• Measure at 10 mm from top of lever
N– 45 ± 10 45 ± 20
FORWARD
Travel mm
N–
45 ± 10 45 ± 20
REVERSE
7.8 ± 4.9 15.7
1st – 2nd
Speed switch (Dial switch)

{0.8 ± 0.5} {1.6}


Operating • Engine stopped N 7.8 ± 4.9 15.7
2nd – 3rd
effort • Measure at 10 mm from end of switch knob {kg} {0.8 ± 0.5} {1.6}
7.8 ± 4.9 15.7
3rd – 4th {0.8 ± 0.5} {1.6}
1st – 2nd 30 ± 5 30 ± 10
Travel 2nd – 3rd • Engine stopped deg. 30 ± 5 30 ± 10
3rd – 4th 30 ± 5 30 ± 10
14.7 (+4.9/0)
HOLD o RAISE 29.4
{1.5 (+0.5/0)} {3}

18.6 (+4.9/0)
35.3
RAISE o HOLD
{1.9 (+0.5/0)} {3.6}

12.3 (+4.9/0)
25.7
HOLD o LOWER
Lift arm {1.25 (+0.5/0)} {2.6}
Work equipment control lever

LOWER o HOLD — —
• Engine coolant tempera-
ture: Operating range 18.6 (+4.9/0)
35.3
LOWER o FLOAT {3.6}
Operating • Engine speed: Low idle N {1.9 (+0.5/0)}
effort • Hydraulic oil tempera- {kg}
ture: 21.6 (+4.9/0)
FLOAT o HOLD 39.7
60 – 80°C {4.0}
{2.2 (+0.5/0)}

16.7 (+4.9/0)
32.3
HOLD o DUMP
{1.7 (+0.5/0)} {3.3}

14.7 (+4.9/0)
Bucket HOLD o TILT 29.4
{1.5 (+0.5/0)} {3}

18.6 (+4.9/0)
27.9
TILT o HOLD
{1.9 (+0.5/0)} {2.9}

HOLD o RAISE
Work equipment control lever

46 ± 9 46 ± 12
Lift arm HOLD o LOWER 46 ± 9 46 ± 12
• Engine coolant tempera-
LOWER o FLOAT 14 ± 9 14 ± 12
ture: Operating range
• Engine speed: Low idle HOLD o DUMP 60 ± 9 60 ± 12
Travel mm
• Hydraulic oil tempera-
ture:
Bucket 60 – 80°C HOLD o TILT 46 ± 9 46 ± 12

WA200-6 3
SEN03731-00 20 Standard value table

Machine model WA200-6


Category

Standard value Service limit


Item Measurement conditions Unit
for new machine value

• Engine stopped
Play mm Max. 50 Max. 100
• Machine facing straight to front
• Flat, level, straight, dry, and paved road 9.8 ± 2.9 Max.14.7
Operating effort N {kg}
Steering wheel

• Engine speed: Low idle (Bucket empty) {1.0 ± 0.3} {Max. 1.5}
• Engine speed: High idle
Turns (Not including play) Turns 4.1 ± 0.4 4.1 ± 0.8
• Left lock – right lock

Low idle • Engine started 3.7 ± 0.4 Max. 4.8


Operating • Hydraulic oil temperature: Within operating
sec.
time range
High idle • Left lock – right lock 3.7 ± 0.3 3.7 ± 1

Beginning of 24.5 – 37.8



Operating depression • Engine started {2.5 – 3.9}
Accelerator pedal

N {kg}
effort • Measure at 150 mm from fulcrum of pedal. 45.5 – 58.8
Full open —
{4.6 – 6.0}

Neutral (α1) a For measuring posture, see Fig. A at end of 45 ± 2 —


Operating this section
deg.
angle • Engine started
Stroke (α) • α = α1 - α2 17 ± 2 —

• Operating angle: 20°


• Engine speed: Low idle 294 ± 30 Min. 238
Operating effort N {kg}
• Hydraulic oil temperature: Within operating {30 ± 3.0} {Min. 24.3}
range
Brake pedal

Neutral (α1) a For measuring posture, see Fig. B at end of 50 —


Operating
angle this section
Max. (α2) • Engine speed: Low idle deg. 20 (+2/0) —
• Hydraulic oil temperature: Within operating
range
Play 5±1 —

HST stall 2,180 ± 100 2,180 (+115/–200)


Engine speed

• Engine coolant temperature: Within operating


range
Hydraulic stall rpm 2,070 ± 100 2,070 ± 200
• HST oil temperature: 60 – 80°C
• Hydraulic oil temperature: 45 – 55°C
HST stall + hydraulic stall 2,060 (+110/–200) 2,060 (+210/–300)

1st 4 ± 0.2 4 ± 0.3


Power train (HST)

2nd 13 ± 0.7 13 ± 0.9


Travel speed
FORWARD km/h
(Bucket empty)
3rd 20 ± 1.0 20 ± 1.4

4th 34.5 ± 1.7 34.5 ± 2.4

4 WA200-6
20 Standard value table SEN03731-00

Machine model WA200-6


Category

Standard value Service limit


Item Measurement conditions Unit
for new machine value

1st 4 ± 0.2 4 ± 0.3

2nd 13 ± 0.7 13 ± 0.9


Travel speed
REVERSE km/h
(Bucket empty)
3rd 20 ± 1.0 18 ± 1.3

4th 34.5 ± 1.7 34.5 ± 2.4

• Engine speed: Full speed


• Hydraulic oil temperature: 45 – 55°C 45.6 (+1.0/-2.5)
High pressure 45.6 ± 1.0
• Directional lever: FORWARD
cut-off pressure {465 ± 10} {465 (+10/-25)}
• Speed switch: 2nd speed
• Traction control switch: ON
Low pressure
• Engine speed: Full speed
relief pressure 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
• Hydraulic oil temperature:
Power train (HST)

(Work equip-
45 – 55°C {25.5 (+2/0)} {25.5 (+2/-1)}
ment PPC cir-
• Directional lever: N
cuit pressure)
• Engine speed: 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
HST oil Full speed When brake pedal releasing
pressure Servo piston • Hydraulic oil {25.5 (+2/0)} {25.5 (+2/-1)}
control oil pres- temperature:
sure 45 – 55°C
When brake pedal depress- Max. 0.6 Max. 0.6
• Directional ing MPa {Max. 6} {Max. 6}
lever: N {kg/
cm2}
• Hydraulic oil temperature: 45 – 55°C
• Gear speed selector switch: 1st
Servo piston • Travel speed control dial: “1” on Min. side 2.5 (+0.2/0)
operating pres- • Directional lever: Measure in both forward 2.5 ± 0.2
{25.5 (+2/0)} {25.5 ± 2}
sure and reverse position.
• Measure while driving at full throttle (Max.
speed: 5 km/h).
• Hydraulic oil temperature:
45 – 55°C 2.5 (+0.2/0) 2.5 (+0.2/-0.1)
Clutch control
Transfer • Directional lever: FORWARD
pressure {25.5 (+2/0)} {25.5 (+2/-1)}
• Speed switch: 3rd or 4th speed
• Travel at a speed of at least 10 km/h
• Engine speed: High idle
Steering

20.6 ± 0.7 20.6 ± 2.0


Steering relief pressure • Hydraulic oil temperature:
{210 ± 7} {210 ± 20}
45 – 55°C
• Tire size:
• Flat, horizontal, straight, 17.5 – 20
dry paved road surface • Speed when
• Braking delay: Within 0.1 m Max. 5 Max. 5
applying
sec brake:
Wheel brake

• Brake pedal operating 20 km/h


Performance effort:
322 N {33 kg} • Tire size:
• Tire inflation pressure: 20.5 – 25
Specified pressure • Speed when
m Max. 12 Max. 12
• Measure braking dis- applying
tance brake:
35 km/h
Disc wear • Thickness of lining mm 1 ± 0.1 Max. 0.6
• Tire inflation pressure: Specified pressure
Parking brake

• Flat paved road with 1/5 (11°20') grade


Performance • Machine at operating condition — Holds position Holds position
a For measuring posture, see Fig. C and Fig. D
at the end of this section

WA200-6 5
SEN03731-00 20 Standard value table

Machine model WA200-6


Work equipment control valve Category

Standard value Service limit


Item Measurement conditions Unit
for new machine value

• Engine speed: High idle MPa 20.6 ± 0.4 20.6 ± 2.0


Relief pressure • Hydraulic oil temperature: {kg/ {210 ± 4} {210 ± 20}
45 – 55°C cm2}

• Engine speed: High idle RAISE 5.5 ± 0.5 Max. 8.2


Lift arm • Hydraulic oil tempera- *1
LOWER 3.6 ± 0.5 Max. 4.7
ture:
45 – 55°C TILT 2.3 ± 0.3 Max. 3.8
Speed • Steering valve: Neutral *2 Sec.
• Apply no load DUMP 1.4 ± 0.3 Max. 2.5
Bucket
a For measuring posture,
Work equipment

see Fig. E – Fig. H at the TILT *3 1.4 ± 0.3 Max. 2


end of this section

Bucket no load

Position of work equipment: Lift arm and
Lift arm cylin-
der bucket in level position Max. 20 Max. 30
• Engine stopped
• Hydraulic oil temperature:
Hydraulic drift mm
45 – 55°C
• Stop engine and leave for 5 minutes, then
Bucket cylinder measure for 15 minutes. Max. 17 Max. 20
a For measuring posture, see Fig. J at the end of
this section
• Engine speed: High idle
Hydraulic drive fan

• Engine coolant temperature: Min. 90°C


Max. fan speed rpm 1,750 ± 50 1,750 ± 100
• Boost temperature: Min. 70°C
• HST oil temperature: Min. 95°C
• Engine speed: High idle
MPa
• Engine coolant temperature: Min. 90°C 14.7 ± 1.5 14.7 ± 2.3
Fan drive pressure {kg/
• Boost temperature: Min. 70°C {150 ± 15} {150 ± 23}
cm2}
• HST oil temperature: Min. 95°C
Proximity switch

Clearance between bucket


3–5 —
positioner switch
• Hydraulic oil temperature:
mm
45 – 55°C
Clearance between boom kick-
3–5 —
out switch

*1: Time taken to raise bucket from contact with ground (bottom of bucket horizontal) to max. height of lift
arm.
*2: Time taken to move bucket from max. tilt to max. dump.
*3: Time taken to move bucket from horizontal position to max. tilt.

6 WA200-6
20 Standard value table SEN03731-00

Machine posture and procedure for performance measurement

a Fig. A a Fig. D

a Fig. B a Fig. E

a Fig. C a Fig. F

WA200-6 7
SEN03731-00 20 Standard value table

a Fig. G

a Fig. H

a Fig. J

8 WA200-6
20 Standard value table SEN03731-00

WA200-6 9
SEN03731-00

WA200-6 Wheel loader


Form No. SEN03731-00

© 2007 KOMATSU
All Rights Reserved
Printed in Japan 07-07 (01)

10
SEN03732-00

WHEEL LOADER 1SHOP MANUAL

WA200-6

Machine model Serial number

WA200-6 70001 and up

30 Testing and adjusting 1


Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 8
Measuring exhaust gas color ........................................................................................................................ 10
Adjusting valve clearance ............................................................................................................................. 12
Measuring compression pressure................................................................................................................. 14
Measuring blow-by pressure......................................................................................................................... 17
Testing engine oil pressure ........................................................................................................................... 18
Measuring intake air (boost) pressure .......................................................................................................... 19
Handling fuel system equipment................................................................................................................... 21
Releasing residual pressure in fuel system .................................................................................................. 21
Measuring fuel pressure ............................................................................................................................... 22
Measuring fuel return rate and leakage ........................................................................................................ 24
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing leakage in fuel system ...................................................................................................................... 29
Handling reduced cylinder mode operation .................................................................................................. 30
Handling no-injection cranking operation...................................................................................................... 30

WA200-6 1
SEN03732-00 30 Testing and adjusting

Handling controller voltage circuit ................................................................................................................. 31


Check of muffler and muffler stack for looseness and damage .................................................................... 31
Check of muffler function .............................................................................................................................. 32
Check of installed condition of cylinder head and manifolds......................................................................... 32
Check of engine piping for damage and looseness ...................................................................................... 33
Testing and adjusting air conditioner compressor belt tension...................................................................... 33
Replacing alternator belt ............................................................................................................................... 34

2 WA200-6
30 Testing and adjusting SEN03732-00

Tools for testing, adjusting, and troubleshooting 1

Testing and Sym- Q'ty


Part No. Part Name Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Measuring exhaust gas
A Commercially
color 2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve
B Commercially
clearance 2 Clearance gauge 1
available
1 795-799-6700 Puller 1 For 107E-1 engine
Measuring compression 2 795-502-1590 Gauge assembly 1 0 – 7 MPa {0 – 70 kg/cm2}
C
pressure 3 795-790-4410 Adapter 1 For 107E-1 engine
4 6754-11-3130 Gasket 1 For 107E-1 engine
Measuring blow-by
D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester
Measuring engine oil 1 1 {25, 60, 400, 600 kg/cm2}
E
pressure 790-261-1204 Digital hydraulic tester Pressure gauge: 60 MPa {600 kg/cm2}
2 799-101-5160 Nipple 1
Measuring intake air
F 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

Measuring fuel 6732-81-3170 Adapter 1 10 × 1.0 mm o R1/8


G 2
compression pressure 6215-81-9710 O-ring 1
3 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
2 795-790-6700 Adapter 1
6754-71-5340 Connector 1
3
6754-71-5350 Washer 1
Measuring fuel return Commercially
H 4 Measuring cylinder 1
rate and leakage available
Commercially
5 Stopwatch 1
available
Commercially Hose
6 1
available (Inside diameter: 14 mm)
Testing accelerator
J 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
pedal
1 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing directional lever K Commercially
2 Scale 1
available
Pressure gauge: 2.5, 6, 40, 60 MPa
Testing and adjusting 799-101-5002 Analog hydraulic tester 1
L {25, 60, 400, 600 kg/cm2}
HST oil pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

WA200-6 3
SEN03732-00 30 Testing and adjusting

Testing and Sym-


Part No. Part Name Q'ty Remarks
adjusting item bol
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Analog hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing clutch control 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
M
pressure
799-401-3100 Adapter 1
2 For hose size #02
02896-11008 O-ring 1
Testing steering wheel N 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Pressure gauge: 2.5, 6, 40, 60 MPa
Testing and adjusting 799-101-5002 Analog hydraulic tester 1
P {25, 60, 400, 600 kg/cm2}
steering oil pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 799-205-1100 Tachometer kit 1 Digital display: 6 – 99999.9 rpm
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Analog hydraulic tester 1
2 {25, 60, 400, 600 kg/cm2}
Testing hydraulic fan Q
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
799-401-3300 Adapter 1
3 For hose size #04
02896-11012 O-ring 1
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Analog hydraulic tester 1
accumulator charge R {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Testing wheel brake oil
S 4 790-301-1720 Adapter 1 20 × 1.5 mm o R1/8
pressure
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Holding work equip-
T 793-463-1100 Stopper 1
ment position
Testing wear of brake
U 418-98-31110 Testing gauge 1 Component part of tool kit
disc
Testing and adjusting
parking brake control V 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
cable
1 79A-264-0021 Push-pull scale 1 0 – 300 N {0 – 30 kg}
Testing work equip-
W Commercially
ment lever 2 Scale 1
available
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Analog hydraulic tester 1
work equipment oil X {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa


799-101-5002 Analog hydraulic tester 1
work equipment PPC Y {25, 60, 400, 600 kg/cm2}
oil pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

4 WA200-6
30 Testing and adjusting SEN03732-00

Testing and Sym-


Part No. Part Name Q'ty Remarks
adjusting item bol
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 REL-5P (5 pins)
799-601-7310 T-adapter 1 SWP (12 poles)
799-601-7070 T-adapter 1 SWP (16 poles)
799-601-4101 T-adapter assembly 1 Connected with engine
Diagnosis for engine
related controller, sen- 799-799-5530 • T-adapter 1 Engine coolant temperature
Z
sor actuator and har- 799-601-4230 • T-adapter 1 Boost temperature/pressure sensor
ness
799-601-4130 • T-adapter 1 Ne sensor, CAM sensor
799-601-4160 • T-adapter 1 Hydraulic pressure sensor
799-601-4211 • T-adapter 1 Controller (50 poles)
799-601-4220 • T-adapter 1 Controller (60 poles)
799-601-4140 • T-adapter 1 Atmospheric pressure sensor
799-601-4340 • T-adapter 1 Pump actuator
799-601-4260 • T-adapter 1 Controller (4 poles)
799-601-4190 • T-adapter 1 Common rail pressure sensor
799-601-2500
or
799-601-2700
or
799-601-2800
or
799-601-2900 T-adapter 1 799-601-2900 is not supplied
or
799-601-7100
or
799-601-4700
or
799-601-8000
799-601-2600 • T-adapter box 1 Econo (Excl. 799-601-2700)
799-601-2740 • Adapter for MIC 1 For MIC-5P
Diagnosis for chassis 799-601-4101 T-adapter assembly 1
related controller, sen-
Z 799-601-4211 • Adapter for DRC 1 For DRC50
sor actuator and har-
ness 799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
799-601-7010 • Adapter for X 1 For X1P
799-601-7020 • Adapter for X 1 For X2P
799-601-7030 • Adapter for X 1 For X3P
799-601-7040 • Adapter for X 1 For X4P
799-601-7050 • Adapter for SWP 1 For SWP6P

WA200-6 5
SEN03732-00 30 Testing and adjusting

Testing and Sym-


Part No. Part Name Q'ty Remarks
adjusting item bol
799-601-7060 • Adapter for SWP 1 For SWP8P (Excl. 799-601-8000)
For M1P (Excl. 799-601-7000 and
799-601-7080 • Adapter for M 1
799-601-7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7110 • Adapter for M 1 For M3P
799-601-7120 • Adapter for M 1 For M4P
799-601-7130 • Adapter for M 1 For M6P
799-601-7150 • Adapter for S 1 For S10P
799-601-7180 • Adapter for AMP040 1 For A8P (799-601-7400 only)
For A12P (Excl. 799-601-7000 and
799-601-7190 • Adapter for AMP040 1
799-601-7100)
799-601-7330 • Adapter for S 1 For S16PW (799-601-8000 only)
799-601-7320 Adapter for SWP 1 For SW16P
799-601-7340 Adapter for M 1 For M8P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7370 Adapter for relay 1 For REL-6P
799-601-7500 T-adapter assembly 1
799-601-7520 • Adapter for 070 1 For 070-12P
799-601-7530 • Adapter for 070 1 For 070-14P
Diagnosis for chassis 799-601-7540 • Adapter for 070 1 For 070-18P
related controller, sen- 799-601-7550 • Adapter for 070 1 For 070-20P
Z
sor actuator and har-
ness 799-601-9000
or T-adapter assembly 1
799-601-9200
For DT2P (Incl. in 799-601-9020
799-601-9020 • Adapter for DT 1
and 799-601-7000)
799-601-9030 • Adapter for DT 1 For DT3P
For DT4P (Incl. in 799-601-9020
799-601-9040 • Adapter for DT 1
and 799-601-7000)
799-601-9050 • Adapter for DT 1 For DT6P
799-601-9060 • Adapter for DT (Gray) 1 For DT8PGR
799-601-9070 • Adapter for DT (Black) 1 For DT8PB
799-601-9080 • Adapter for DT (Green) 1 For DT8PG
799-601-9110 • Adapter for DT (Gray) 1 For DT12PGR
799-601-9120 • Adapter for DT (Black) 1 For DT12PB
799-601-9130 • Adapter for DT (Green) 1 For DT12PG
799-601-9140 • Adapter for DT (Brown) 1 For DT12P
799-601-9300 T-adapter assembly 1
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
• Multi-adapter for
799-601-9890 1 For DT2–4, DTM2
DT2–4, DTM2
Measuring coolant and
— 799-101-1502 Digital thermometer 1
oil temperature
Measuring time and Commercially
— Stopwatch 1
speed available

6 WA200-6
30 Testing and adjusting SEN03732-00

Testing and Sym-


Part No. Part Name Q'ty Remarks
adjusting item bol
Measuring voltage and Commercially
— Tester 1
resistance available
Removal and installation
Commercially 3.26 mm TORX wrench
of boost pressure and — TORX wrench 1
available (KTC Q4T15 or equivalent)
temperature sensor
Removal and installation
Commercially 21 mm deep socket
of engine coolant — Deep socket 1
available (MITOLOY 4ML-21 or equivalent)
temperature sensor

WA200-6 7
SEN03732-00 30 Testing and adjusting

Measuring engine speed 1 2. Measuring HST stall speed


1) Referring to “Special function of machine
k Put chocks under the tires securely. monitor”, select the real time monitoring
k When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01001: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.04408: HST OIL TEMP
Within operating range (HST oil temperature)
q HST oil temperature:
Within operating range

1. Measuring engine speed (low idle and high


idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Display “ENG SPEED” from the monitor-
ing items of the machine monitor.
a Monitoring item
Code No. 01001: ENG SPEED
(Engine speed)

3) Start the engine.


4) Lower the bucket to near the ground, then
drive the machine forward and thrust the
bucket into the stockpile of soil or rock
(portion a).

3) Start the engine, set it in the measuring


condition, and measure the engine speed.

5) While running the engine at high idle,


press the accelerator pedal gradually.
When the HST stalls, measure the engine
speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the HST for more
than 20 seconds. Take care that the
HST oil temperature will not exceed
120°C.

8 WA200-6
30 Testing and adjusting SEN03732-00

3. Measuring hydraulic stall speed 4. Measuring HST stall and hydraulic stall (full
1) Referring to “Special function of machine stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing HST stall speed”.
2) Display “ENG SPEED” from the monitor- 2) Start the engine.
ing items of the machine monitor. 3) Lower the bucket to near the ground, then
a Monitoring item drive the machine forward and thrust the
Code No. 01001: ENG SPEED bucket into the stockpile of soil or rock
(Engine speed) (portion a).

3) Run the engine at high idle. 4) While running the engine at high idle, stall
4) Relieve the lift arm cylinder or bucket cyl- the HST and relieve the lift arm cylinder or
inder on the extraction side and measure bucket cylinder on the extraction side
the engine speed. simultaneously and measure the engine
a Finish measurement in a short time speed at this time.
so that the hydraulic oil temperature a Do not keep stalling the HST for more
will not exceed 120°C. than 20 seconds. Take care that the
HST oil temperature will not exceed
120°C.

WA200-6 9
SEN03732-00 30 Testing and adjusting

Measuring exhaust gas color 1 2. Measuring with smoke meter A2


1) Insert the probe of smoke meter A2 in the
a Necessary tools outlet of the muffler (exhaust pipe) and fix
Symbol Part No. Part Name it to the exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available

k When installing and removing the measuring


instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the fol-
lowing condition.
q Engine coolant temperature: Within oper-
ating range
2) Connect the probe hose, receptacle of the
1. Measuring with handy smoke checker A1 accelerator switch, and air hose to smoke
1) Stick a sheet of filter paper to smoke meter A2.
checker A1. a Keep the pressure of the supplied
2) Insert the exhaust gas intake pipe in the compressed air at 1.5 MPa {15 kg/
muffler (exhaust pipe). cm2} or below.
3) Start the engine and heighten the engine 3) Connect the power cable to a 100 V AC
coolant temperature to the operating range. receptacle.
4) Accelerate the engine suddenly and run it a Confirm that the smoke meter power
at HST stalling and hydraulic stalling, and switch is in the OFF position, before con-
operate the handle of smoke checker A1 necting the power cable to an outlet.
so that the filter paper will absorb the 4) Loosen the cap nut of the suction pump
exhaust gas. and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter A2.

5) Take out the filtering paper and compare it


with the attached scale for judgement.
6) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.

10 WA200-6
30 Testing and adjusting SEN03732-00

6) Start the engine and keep it running until


the engine coolant temperature rises to
the operating range.
7) Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal
of smoke meter A2 and collect the
exhaust gas into the filter paper.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets)
in the filtering paper holder, and read the
indicated value.
9) After finishing work, remove the used
instruments and return the removed parts.

WA200-6 11
SEN03732-00 30 Testing and adjusting

Adjusting valve clearance 1 5. Remove plate (4) and plug (5) under the start-
ing motor and insert gear B1.
a Necessary tools
Symbol Part No. Part Name
1 795-799-1131 Gear
B Commercially
2 Clearance gauge
available

a Adjust the valve clearance under the following


condition.
q Engine coolant temperature: Normal tem-
perature

1. Open the engine right and left side covers.

2. Remove blow-by duct (2) and bracket (3) of


cylinder head cover (1). 6. Rotate the crankshaft forward (clockwise, see-
ing from the fan) with gear B1 and set wide slit
3. Remove cylinder head cover (1). (b) of the rotation sensor ring to projection top
a The engine hood does not need to be (a) of front cover.
removed. a Projection top (a) must be within the range
of wide slit (b) when it is seen from the air
conditioner compressor side.
a After the above positioning, the No. 1 cyl-
inder or No. 4 cylinder is not at the top
dead center (TDC). Take care. (The cylin-
der is at 76 – 88° before the top dead cen-
ter.)

4. Remove 2 bolts (7) of relay (6) under the start-


ing motor and move the relay.

7. Check the movement of the rocker arm of the


No . 1 c yl i nd er to j u dg e th e va l ve to b e
adjusted.

a If you can move the rocker arms of air


intake valves (IN) with the hand by the
valve clearance, adjust the valves marked
with Q in the valve arrangement drawing.
a If you can move the rocker arms of
exhaust valves (EX) with the hand by the
valve clearance, adjust the valves marked
with q in the valve arrangement drawing.
a Valve arrangement drawing

12 WA200-6
30 Testing and adjusting SEN03732-00

a If the valves marked with Q in the valve


arrangement drawing were adjusted in
steps 7 and 8, adjust the valves marked
with q.

11. After finishing adjustment, remove the adjust-


ing tools and return the removed parts.
a Remove gear B1 without fail.
3 Cylinder head cover mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}

8. Adjust the valve clearance according to the fol-


lowing procedure.
1) While fixing adjustment screw (10), loosen
locknut (11).
2) Insert clearance gauge B2 in the
clearance between rocker arm (12) and
crosshead (13) and adjust the valve
clearance with adjustment screw (10).
a With the clearance gauge inserted,
turn the adjustment screw to a degree
that you can move the clearance
gauge lightly.
3) While fixing adjustment screw (10), tighten
locknut (11).
3 Locknut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.

9. Rotate the crankshaft forward by 1 turn and set


wide slit (b) to projection top (a) according to
step 6.

10. Adjust the other valve clearances according to


steps 7 and 8.
a If the valves marked with q in the valve
arrangement drawing were adjusted in
steps 7 and 8, adjust the valves marked
with Q.

WA200-6 13
SEN03732-00 30 Testing and adjusting

Measuring compression 4. Loosen injector terminal nut (4) and remove


pressure 1 the terminal from the injector.

a Necessary tools 5. Set the cylinder to be checked to the compres-


Symbol Part No. Part Name sion top dead center.
a How to turn the crankshaft, refer to
1 795-799-6700 Puller
“Adjusting valve clearance”.
2 795-502-1590 Gauge assembly a When the cylinder is at the compression
C
3 795-790-4410 Adapter top dead center, the rocker arm of the cyl-
4 6754-11-3130 Gasket inder can be moved by the valve clear-
ance with the hand.
k When measuring the compression pres-
sure, take care not to burn yourself on the 6. Remove rocker arm assembly (5).
exhaust manifold or muffler or get caught
in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C)

1. Remove cylinder head cover (1). For details,


see Disassembly and assembly, “Removal and
installation of cylinder head assembly”.

2. Disconnect 2 injector wiring harness connec-


tors (2) and move the wiring harnesses.

7. Remove retainer (6) and fuel inlet connector (7).

8. Remove holder (8).

9. Remove injector (9).


a Using puller C1, remove the injector with
impacts of a slide hammer.
a Do not remove the injector by prying its
top up.

3. Disconnect fuel high-pressure tube (3).

14 WA200-6
30 Testing and adjusting SEN03732-00

16. Rotate the engine with the starting motor and


measure the compression pressure.
a Read the gauge when its pointer is stabi-
lized.

17. After finishing measurement, remove the mea-


suring tools and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) While matching projection (a) of the injec-
tor to notch (b) of the holder, set the injec-
tor to the cylinder head.
a When setting the injector, direct the
above matching position toward the
10. Fit gasket C4 to the end of adapter C3 and fuel inlet connector insertion side.
insert them in the injector mounting portion.

11. Fix adapter C3 with injector holder.


a Tighten the holder mounting bolts alter-
nately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.8 ± 0.08 kgm}

12. Connect gauge assembly C2 to adapter C3.


a If engine oil is applied thinly to the con-
necting parts of the adapter and gauge, air
does not leak easily.

13. Install rocker arm assembly (5).


3 Rocker arm assembly mounting bolt: 2) Tighten injector holder mounting bolts (10)
36 ± 5 Nm {3.67 ± 0.51 kgm} by 3 – 4 turns.
3) Set fuel inlet connector (7).
14. Adjust the valve clearance. a Push in the fuel inlet connector until
a See “Adjusting valve clearance”.