Komatsu Wheel Loader WA200-6 WA200PZ-6 service & repair manual

Description Komatsu Wheel Loader WA200-6 WA200PZ-6 service & repair manual

Komatsu Wheel Loader WA200-6, WA200PZ-6 pdf workshop service manual + operation & maintenance manual

Serial numbers:
WA200-6 70001 and up, 72001 and up, 75001 and up, C10172 and up
WA200PZ-6 70001 and up, 70136 and up, H00051 and up

Specifications, testing, adjusting, troubleshooting, technical documentation, electrical wiring diagrams, hydraulic schematics, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Composition of shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification dimension drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine mount and transfer mount
Damper
Cooling system
Cooling system hydraulic piping diagram
Cooling fan motor
Power train
Power train system diagram
Drive shaft
HST hydraulic piping diagram
HST pump
HST motor
Transfer
Clutch solenoid valve
Axle
Differential
Torque proportioning differential
Limited slip differential
Final drive
Steering system
Steering piping diagram
Steering column
Priority valve
Orbit-roll valve
2-way restrictor valve
Cushion valve
Steering cylinder
Emergency steering piping diagram
Emergency steering valve
Steering relief valve
Brake system
Brake piping diagram
Charge valve
Brake valve
Inching valve
Accumulator (for brake)
Slack adjuster
Brake
Parking brake control
Parking brake
Undercarriage and frame
Axle mount and center hinge pin
Tires
Hydraulic system
Work equipment hydraulic piping diagram
Work equipment control lever linkage
Hydraulic tank
4-gear pump
Work equipment control valve
PPC valve
Lock valve
Accumulator (for PPC circuit)
Bypass valve
Quick coupler solenoid valve
ECSS valve
Accumulator (for ECSS)
Work equipment
Work equipment linkage
Bucket
Bucket positioner and boom kick-out
Work equipment cylinder
Cab and its attachments
Cab
Air conditioner
Electrical system
Machine monitor system
Machine monitor
Rearview monitor system
Electrical system (HST controller system)
HST controller
ECSS system
KOMTRAX system
Engine starting circuit
Engine stopping circuit
Preheating circuit
Engine output derating function
Automatic warm-up function
Parking brake circuit
Coupler plunger control system
Max. traction switch
Multi-function knob
Sensor

Standard value table
Standard service value table
Standard service value table for engine
Standard service value table for chassis

Testing and adjusting
Precautions before work
Tools for testing, adjusting, and troubleshooting
Sketches of special tools
Measuring engine speed
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Testing engine oil pressure
Measuring intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking leakage in fuel system
Handling cylinder cut-out mode operation
Handling no-injection cranking operation
Handling controller voltage circuit
Check of muffler and muffler stack for looseness and damage
Check of muffler function
Check of installed condition of cylinder head and manifolds
Check of engine piping for damage and looseness
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Checking operating force of accelerator pedal
Checking directional lever
Testing and adjusting HST oil pressure
Testing clutch control pressure
Testing and adjusting steering wheel
Testing and adjusting steering oil pressure
Bleeding air from steering circuit
Testing hydraulic fan
Measuring brake pedal
Testing and adjusting brake pedal linkage
Measuring brake performance
Testing and adjusting accumulator charge pressure
Testing wheel brake oil pressure
Testing wear of brake disc
Bleeding air from wheel brake circuit
Releasing residual pressure in brake accumulator circuit
Testing parking brake performance
Testing and adjusting parking brake control cable
Measuring and adjusting work equipment control lever
Testing and adjusting work equipment hydraulic pressure
Testing work equipment PPC oil pressure
Bleeding air from hydraulic circuit
Releasing remaining pressure in hydraulic circuit
Testing and adjusting bucket positioner
Testing and adjusting boom kick-out switch
Checking proximity switch operation pilot lamp
Procedure for testing diodes
Preparation work for troubleshooting for electric system
Starting KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Adjustment of rearview camera angle
Adjusting machine monitor
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
Special functions of machine monitor (EMMS)
Pm clinic inspection chart

Troubleshooting
Failure code table and fuse locations
Precautions before work
Failure codes table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Testing before troubleshooting
Classification and procedures of troubleshooting
Information contained in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
Precautions before work
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine hood assembly
Removal and installation of radiator
Removal and installation of air aftercooler
Removal and installation of hydraulic oil cooler assembly
Removal and installation of engine assembly
Removal and installation of engine front oil seal assembly
Removal and installation of engine rear oil seal assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of fuel tank assembly
Power train
Disassembly and assembly of transfer assembly
Removal and installation of parking brake assembly
Disassembly and assembly of parking brake assembly
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Disassembly and assembly of axle housing assembly
Disassembly and assembly of differential assembly
Undercarriage and frame
Removal and installation of center hinge pin
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of HST pump and 4-gear pump assembly
Disassembly and assembly of HST pump assembly
Removal and installation of HST motor 1 assembly
Removal and installation of HST motor 2 assembly
Disassembly and assembly of HST motor assembly
Removal and installation of work equipment control valve assembly
Removal and installation of hydraulic tank
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator's cab and floor frame assembly
Removal and installation of operator's cab glass (Stuck glass)
Removal and installation of air conditioner unit
Electrical system
Removal and installation of monitor panel
Removal and installation of engine controller assembly
Removal and installation of HST controller assembly
Removal and installation of KOMTRAX terminal assembly

Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Common electrical circuit diagram
Specific electrical circuit diagram
Connector list and stereogram

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