Komatsu Wheel Loader WA200-5H WA200PT-5H service & repair manual

Description Komatsu Wheel Loader WA200-5H WA200PT-5H service & repair manual

Komatsu Wheel Loader WA200-5H, WA200PT-5H pdf workshop service manual

Serial numbers:
WA200-5H H50051 and up
WA200PT-5H H60051 and up

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

MANUAL CONTENT:
SAFETY
FOREWORD
SAFETY NOTICE
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

GENERAL
GENERAL ASSEMBLY DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND COOLANT

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Engine mount and transfer mount
Damper
Cooling system
Transfer oil cooler
Power train
Power train system diagram
Drive shaft (propeller shaft)
HST hydraulic piping diagram
HST pump
High-pressure relief valve
Low-pressure relief valve
HST charge pump
Speed-related valve (DA valve)
High-pressure cut-off valve
HST motor
EP servo valve
HA servo valve
Forward-reverse shuttle valve
Transfer
Clutch solenoid valve
Axle
Differential
Limited-slip differential
Final drive
Axle mounting and center hinge pin
Steering piping
Steering column
Priority valve
Orbit-roll valve
2-way restrictor valve
Cushion valve
Steering cylinder
Emergency steering piping
Emergency steering valve
Brake piping
Brake valve
Inching valve
Charge valve
Accumulator (for brake)
Slack adjuster
Brake
Parking brake control
Parking brake
Hydraulic piping
Work equipment lever linkage
Hydraulic tank
4-gear pump unit
Accumulator (for PPC circuit)
Lock valve
Bypass valve
Quick coupler valve
E.C.S.S. valve
Accumulator (for E.C.S.S.)
Hydraulic piping of cooling system
Cooling fan motor
Work equipment control valve
Work equipment PPC valve
Attachment PPC valve
Work equipment linkage
Bucket
Control of bucket positioner, boom kick-out, and dump speed
Work equipment cylinder
Air conditioner
Machine monitoring system
Machine monitor
List of items displayed on monitor
Electrical system (HST controller system)
HST controller
Function of selecting directional selector switch
Engine start circuit
Engine stop circuit
Preheating circuit
Parking brake circuit
Electronically controlled suspension system
Sensors

TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Testing and adjusting fuel injection timing
Measuring engine oil pressure
Measuring, testing operating force of accelerator pedal
Adjusting engine stop solenoid
Adjusting engine speed sensor
Measuring directional lever
Testing and adjusting HST oil pressure
Measuring 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
Measuring brake oil pressure
Measuring wear of brake disc
Bleeding air from brake circuit
Measuring 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 and adjusting work equipment PPC oil pressure
Bleeding air
Releasing remaining pressure in hydraulic circuit
Testing and adjusting bucket positioner
Testing and adjusting of boom kick-out
Checking proximity switch actuation display lamp
Procedure for checking diode
Method of connecting T-adapter for HST controller
Special functions of machine monitor
Flow of modes and functions

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECK BEFORE TROUBLESHOOTING
Categories, procedure, and method of using troubleshooting charts
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING No.
Connection table for connector pin numbers
T-ADAPTER TABLE
CONNECTOR TYPES AND MOUNTING LOCATIONS
Connector layout drawing
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
HST controller system diagram
Before troubleshooting code display
Before troubleshooting electrical system
Information contained in troubuleshooting table
TROUBLESHOOTING OF monitor SYSTEM (mon MODE)
Monitor system circuit diagram
Before troubleshooting code display
Before troubleshooting electrical system
Information contained in troubuleshooting table
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
Electrical system diagram
Parking brake related diagram
Before troubleshooting electrical system
Information contained in troubuleshooting table
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
Method of using troubleshooting chart
Failure code and cause table
TROUBLESHOOTING OF ENGINE (S MODE)

DISASSEMBLY AND ASSEMBLY
Removal and installation of fuel injection pump assembly
Removal and installation of nozzle holder assembly
Removal and installation of cylinder head assembly
Removal and installation of engine
Removal and installation of radiator assembly
Removal and installation of air aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of cooling fan and fan motor assembly
Removal and installation of fuel tank assembly
Removal and installation of transfer assembly
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
Removal and installation of HST pump and 4-gear pump assembly
Removal and installation of HST motor 1 assembly
Removal and installation of HST motor 2 assembly
Removal and installation of work equipment control valve assembly
Removal and installation of travel damper valve assembly
Removal and installation of hydraulic tank
Removal and installation of work equipment assembly
Disassembly and assembly of hydraulic cylinder assembly
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (stuck glass)
Removal and installation of center hinge pin
Removal and installation of counterweight
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of monitor panel
How to read this manual
Precautions when performing operation
Special tool list
Sketches of special tools

OTHERS
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

Engine SAA6D102E-2 workshop service manual