Komatsu Wheel Loader WA200-7 sn:80001 and up Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Komatsu Wheel Loader WA200. 
Original factory manuals for Komatsu Loaders, Dozers, Excavators contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks
 
Covered models:
    WA200-7 sn:80001 and up
 
Format: PDF, 1556 Pages
Language: English
 
Contents:
    00 Index and foreword
        Index and foreword 
        Foreword, safety and general information
        Important safety notice 
        How to read the shop manual
        Explanation of terms for maintenance standard 
        Handling equipment of fuel system devices 
        Handling of intake system parts 
        Handling of hydraulic equipment 
        Method of disconnecting and connecting of push-pull type coupler 
        Handling of electrical equipment 
        How to read electric wire code 
        Precautions when performing operation
        Practical use of KOMTRAX 
        Standard tightening torque table 
        List of Abbreviation 
        Conversion table
    01 Specifications
        Specifications 
        Specification dimension drawing 
        Specifications 
        Weight table
        Table of fuel, coolant, and lubricants
    10 Structure and function
        Engine and cooling system 
        VFT
        EGR system piping drawing 
        EGR system circuit diagram
        EGR valve 
        EGR cooler 
        KCCV layout drawing 
        KCCV ventilator 
        KDOC muffler 
        Damper
        Cooling system
        Cooling system hydraulic piping diagram
        Cooling fan motor 
        Power train 
        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 
        Orbitrol valve 
        Steering column 
        Priority valve
        Emergency steering valve 
        Brake system 
        Brake piping diagram 
        Brake valve
        Charge valve 
        Accumulator (for brake)
        Slack adjuster
        Brake 
        Parking brake control 
        Parking brake 
        Parking brake cylinder
        Parking brake solenoid valve 
        Inching valve 
        Undercarriage and frame 
        Axle mount and center hinge pin
        Hydraulic system
        Hydraulic component layout 
        Work equipment control lever linkage 
        Hydraulic tank
        Accumulator (for PPC circuit) 
        Work equipment control valve 
        PPC valve
        Attachment EPC valve 
        Work equipment lock solenoid valve 
        ECSS valve 
        Accumulator (for ECSS) 
        2-way restrictor valve 
        Cushion valve
        Accumulator (for oil cooler circuit) 
        Quadruple gear pump 
        Quick coupler solenoid valve
        Work equipment
        Work equipment linkage
        Bucket 
        Bucket positioner and boom kick-out 
        Cab and its attachments 
        Cab
        Electrical system
        Machine monitor system 
        Machine monitor
        Electrical system (HST controller system)
        System component parts
        HST controller 
        ECSS
        KOMTRAX system 
        Engine starting circuit
        Engine stopping circuit 
        Preheating system
        Automatic preheating system 
        Manual preheating system 
        Engine output limit function 
        Automatic warm-up function 
        Parking brake control system 
        Multi-function mono-lever 
        Sensor 
    20 Standard value table
        Standard value table 
        Standard value table for engine
        Standard value table for machine
    30 Testing and adjusting
        Related information on testing and adjusting 
        Tools for testing and adjusting
        Engine and cooling system 
        Testing and adjusting engine speed
        Testing exhaust gas temperature 
        Testing exhaust gas color
        Testing and adjusting valve clearance 
        Testing compression pressure 
        Testing blowby pressure
        Testing engine oil pressure 
        Testing boost pressure 
        Handling equipment of fuel system devices 
        Releasing remaining pressure from fuel system 
        Testing fuel pressure 
        Testing fuel discharge, return and leakage 
        Bleeding air from fuel system 
        Testing fuel circuit for leakage
        Handling cylinder cutout mode operation 
        Handling no-injection cranking operation 
        Testing KDPF and muffler stack for looseness and damage 
        Testing KDOC function
        Testing installed condition of cylinder heads and manifolds
        Testing engine piping for damage and looseness 
        Testing and adjusting air conditioner compressor belt tension
        Replacing alternator belt
        Power train 
        Testing oil leakage from axle final drive 
        Testing drive shaft for looseness, backlash, and damage
        Testing accelerator pedal 
        Testing and adjusting HST oil pressure
        Testing transfer clutch control pressure 
        Steering system 
        Testing directional lever
        Testing and adjusting steering wheel 
        Testing work equipment control lever
        Testing and adjusting steering circuit oil pressure
        Bleeding air from steering circuit 
        Brake system 
        Testing brake pedal 
        Testing and adjusting brake pedal and linkage 
        Testing braking performance
        Testing and adjusting accumulator charge pressure
        Testing wheel brake oil pressure
        Testing lowering of wheel brake pressure
        Testing wear of wheel brake disc 
        Bleeding air from wheel brake circuit 
        Releasing remaining pressure in brake accumulator circuit
        Testing parking brake performance
        Testing parking brake release pressure 
        Method of releasing parking brake manually
        Hydraulic system
        Testing and adjusting cooling fan speed 
        Testing cooling fan pump circuit oil pressure 
        Testing work equipment PPC oil pressure 
        Testing and adjusting work equipment oil pressure 
        Bleeding air from each part 
        Releasing remaining pressure in hydraulic circuit 
        Work equipment
        Testing and adjusting bucket positioner 
        Testing and adjusting boom kick-out switch
        Checking the proximity switch working pilot lamp 
        Electrical system
        Adjusting replaced, reassembled or added sensor, controller, etcwith machine monitor
        Special functions of machine monitor
        KOMTRAX terminal start-up procedure 
        Lamp indication of KOMTRAX terminal
        Handling voltage circuit of controller 
        Test diodes
        Pm Clinic
        Pm Clinic service
    40 Troubleshooting
        Related information on troubleshooting 
        Points to remember when performing troubleshooting
        How to proceed in troubleshooting
        Checks before troubleshooting
        Check procedure before troubleshooting 
        Preparation for troubleshooting of electrical system 
        Classification and procedures of troubleshooting
        Symptom and troubleshooting No
        Information described in troubleshooting table
        Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system 
        Connector list and layout
        Connection table of connector by Noof pins
        T-box and T-adapter list 
        Fuse location table 
        Failure code list 
        Troubleshooting by failure code (Display of code)
        Troubleshooting of electrical system (E-mode)…
        Troubleshooting for hydraulic and mechanical system (H-mode) …
        Troubleshooting of engine (S-mode)
    50 Disassembly and assembly
        General information on disassembly and assembly 
        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 engine hood assembly 
        Removal and installation of cylinder head assembly
        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 engine assembly 
        Removal and installation of belt for alternator and air conditioner compressor
        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 
        Removal and installation of KCCV ventilator assembly 
        Removal and installation of KDOC muffler
        Removal and installation of EGR cooler assembly 
        Removal and installation of EGR valve assembly
        Power train
        Removal and installation of transfer assembly
        Disassembly and assembly of transfer assembly 
        Removal and installation of parking brake assembly 
        Removal and installation of parking brake cylinder 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 quadruple type 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 ECSS (Electronically Controlled Suspension System) valve assembl
        Removal and installation of hydraulic tank assembly 
        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 (adhered glass) 
        Disassembly and assembly of operator's seat 
        Removal and installation of air conditioner unit assembly
        Removal and installation of air conditioner compressor assembly
        Electrical system 
        Removal and installation of machine monitor
        Removal and installation of engine controller assembly
        Removal and installation of HST controller assembly 
        Removal and installation of KOMTRAX terminal assembly
    60 Maintenance standard
        Engine and cooling system 
        Engine mount and transfer mount 
        Damper
        Cooling system
        Cooling fan motor 
        Power train 
        Drive shaft 
        Transfer 
        Axle
        Differential 
        Limited slip differential 
        Final drive 
        Steering system 
        Orbitrol valve 
        Steering cylinder
        Steering column
        Priority valve 
        Emergency steering valve 
        Brake system 
        Charge valve 
        Slack adjuster 
        Brake 
        Parking brake 
        Undercarriage and frame 
        Axle mount and center hinge pin 
        Hydraulic system
        Hydraulic tank
        Work equipment control valve 
        PPC valve
        ECSS valve 
        Quadruple gear pump
        Work equipment
        Work equipment linkage
        Bucket 
        Bucket positioner and boom kick-out 
        Work equipment cylinder
    80 Appendix
        Air conditioner 
        Precautions for refrigerant
        Air conditioner component
        Configuration and function of refrigeration cycle 
        Outline of refrigeration cycle
        Air conditioner unit
        Functions of main components in air conditioner unit 
        Blower and intake unit
        Compressor
        Condenser
        Receiver drier 
        Air conditioner control panel
        Procedure for troubleshooting 
        Circuit diagram and arrangement of connector pins 
        System diagram 
        Details of air conditioner unit
        Parts and connectors layout
        Inspection by self-diagnosis function (displays diagnosis on the control panel) 
        Testing temperature control system
        Testing FRESH/RECIRC air changeover 
        Testing evaporator temperature sensor 
        Testing relays 
        Troubleshooting chart 1
        Troubleshooting chart 2
        Information described in troubleshooting table
        Troubleshooting for power supply system (Air conditioner does not operate) 
        Troubleshooting for compressor and refrigerant system (Air is not cooled) 
        Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 
        Troubleshooting for temperature control 
        Troubleshooting for FRESH/RECIRC air changeover
        Connection of service tool 
        Troubleshooting by gauge pressure
        Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
        Handling of compressor oil
    90 Diagrams and drawings
        Hydraulic diagrams and drawings
        Symbols used in hydraulic circuit diagrams 
        Hydraulic circuit diagram 
        Electrical diagrams and drawings 
        Symbols used in electric circuit diagrams 
        Electrical circuit diagram  
    Index .
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