Komatsu 200-1 Shop Manual SEBM0418C102 -PDF DOWNLOAD

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Komatsu 200-1 Shop Manual SEBM0418C102 -PDF DOWNLOAD

FILE DETAILS:

Komatsu 200-1 Shop Manual SEBM0418C102 -PDF DOWNLOAD

Language : English
Pages :449
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu 200-1 Shop Manual SEBM0418C102 -PDF DOWNLOAD

MACHINE MODEL SERIAL No.
WA200-1 10001 and up

COVER 1
CONTENTS 2
10 ENGINE 7
12 TESTING AND ADJUSTING 7
STANDARD VALUE TABLE 8
TOOL LIST FOR TESTING AND ADJUSTING 9
ADJUSTING VALVE CLEARANCE 10
MEASURING COMPRESSION PRESSURE 11
TESTING AND ADJUSTING FUEL INJECTION TIMING 12
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 14
MEASURING BLOW-BY PRESSURE 15
TESTING AND ADJUSTING FAN BELT TENSION 16
MEASURING EXHAUST GAS COLOR 17
MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL 18
13 DISASSEMBLY AND ASSEMBLY 20
STARTING MOTOR 21
REMOVAL 21
INSTALLATION 21
ALTERNATOR 22
REMOVAL 22
INSTALLATION 22
ENGINE OIL COOLER 23
REMOVAL 23
INSTALLATION 23
FUEL INJECTION PUMP 24
REMOVAL 24
INSTALLATION 24
WATER PUMP 25
REMOVAL 25
INSTALLATION 25
NOZZLE HOLDER 26
REMOVAL 26
INSTALLATION 26
CYLINDER HEAD 27
REMOVAL 27
INSTALLATION 32
RADIATOR 38
REMOVAL 38
INSTALLATION 40
ENGINE 42
REMOVAL 42
INSTALLATION 46
FUEL TANK 50
REMOVAL 50
INSTALLATION 51
20 POWER TRAIN 52
21 STRUCTURE AND FUNCTION 52
GENERAL 53
HYDRAULIC CIRCUIT FOR POWER TRAIN 55
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 56
TORQUE CONVERTER AND TRANSMISSION PIPING 57
TORQUE CONVERTER CHARGING PUMP 58
TORQUE CONVERTER 59
TORQUE CONVERTER OIL FILTER 61
TORQUE CONVERTER OIL COOLER 62
TORQUE CONVERTER REGULATOR VALVE 63
TORQFLOW TRANSMISSION 65
CLUTCH PACK 67
TRANSMISSION CONTROL VALVE 71
SELECTOR VALVE 72
UPPER VALVE 73
LOWER VALVE 74
PILOT REDUCING VALVE 75
PRIORITY VALVE, RELIEF VALVE 76
MODULATING RELIEF VALVE 77
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE 78
SPEED SPOOL 82
AXLE 85
DIFFERENTIAL 87
FINAL DRIVE 91
DRIVE SHAFT 92
AXLE MOUNT 93
TIRE AND WHEEL 95
22 TESTING AND ADJUSTING 96
STANDARD VALUE TABLE 97
TOOL LIST FOR TESTING AND ADJUSTING 99
MEASURING ENGINE STALL SPEED100
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION102
MEASURING SHIFT LEVER104
MEASURING VALVE SPOOL OPERATING FORCE AND TRAVEL105
TIRE AND WHEEL107
TROUBLESHOOTING108
PRECAUTIONS WHEN TROUBLESHOOTING109
METHOD OF READING TROUBLESHOOTING TABLE111
PREVENTING RECURRENCE OF TROUBLE113
TROUBLESHOOTING TABLE114
1MACHINE DOES NOT MOVE OFF114
2MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF116
3LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR118
4LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR119
5OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH120
23 DISASSEMBLY AND ASSEMBLY121
TORQUE CONVERTER CHARGING PUMP122
REMOVAL122
INSTALLATION122
TORQUE CONVERTER, TRANSMISSION123
REMOVAL123
INSTALLATION129
TORQUE CONVERTER135
DISASSEMBLY135
ASSEMBLY138
TRANSMISSION141
DISASSEMBLY141
ASSEMBLY148
CLUTCH PACK157
DISASSEMBLY157
ASSEMBLY163
TRANSMISSION CONTROL VALVE176
REMOVAL176
INSTALLATION177
DISASSEMBLY179
ASSEMBLY179
MECHANICAL VALVE181
DISASSEMBLY181
ASSEMBLY182
DRIVE SHAFT183
DISASSEMBLY183
ASSEMBLY185
FRONT AXLE187
REMOVAL187
INSTALLATION189
REAR AXLE191
REMOVAL191
INSTALLATION195
DIFFERENTIAL200
DISASSEMBLY200
ASSEMBLY204
AXLE HOUSING214
DISASSEMBLY214
ASSEMBLY218
24 MAINTENANCE STANDARD224
TRANSMISSION AND ENGINE MOUNT225
TORQUE CONVERTER CHARGING PUMP226
TORQUE CONVERTER 227
TORQUE CONVERTER REGULATOR VALVE228
TRANSMISSION 229
TRANSMISSION CLUTCH ASSEMBLY231
TRANSMISSION CONTROL VALVE233
UPPER VALVE233
LOWER VALVE235
SELECTOR VALVE236
AXLE237
DIFFERENTIAL239
FINAL DRIVE241
DRIVE SHAFT242
AXLE MOUNT243
40 STEERING SYSTEM244
41 STRUCTURE AND FUNCTION244
GENERAL245
HYDRAULIC CIRCUIT FOR STEERING247
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING248
OPERATION OF STEERING VALVE249
TWO-WAY RESTRICTOR VALVE250
STEERING VALVE251
STEERING RELIEF VALVE253
SAFETY VALVE (WITH SUCTION VALVE)254
OPERATION OF DEMAND VALVE255
STEERING COLUMN AND GEAR BOX257
STEERING LINKAGE258
STEERING CYLINDER259
CENTER HINGE PIN260
42 TESTING AND ADJUSTING 261
STANDARD VALUE TABLE262
TOOL LIST FOR TESTING AND ADJUSTING262
MEASURING STEERING WHEEL PLAY263
MEASURING OPERATING FORCE OF STEERING WHEEL264
OPERATING TIME OF STEERING WHEEL265
TESTING STEERING LINKAGE266
ADJUSTING STEERING LINKAGE267
STEERING OIL PRESSURE268
TROUBLESHOOTING269
TROUBLESHOOTING TABLE270
1STEERING WHEEL DOES NOT TURN270
2STEERING WHEEL IS SLUGGISH271
3STEERING WHEEL MOVE UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK272
4MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING272
5LEFT AND RIGHT TURNING RADIUS ARE DIFFERENT272
43 DISASSEMBLY AND ASSEMBLY273
STEERING GEAR BOX274
REMOVAL274
INSTALLATION275
DISASSEMBLY276
ASSEMBLY277
STEERING VALVE279
REMOVAL279
INSTALLATION281
DISASSEMBLY283
ASSEMBLY283
STEERING CYLINDER285
REMOVAL285
INSTALLATION286
DISASSEMBLY287
ASSEMBLY289
CENTER HINGE PIN292
REMOVAL292
INSTALLATION297
44 MAINTENANCE STANDARD302
STEERING VALVE303
STEERING CYLINDER MOUNT304
STEERING CYLINDER 305
STEERING LINKAGE306
CENTER HINGE PIN307
STEERING COLUMN AND GEAR BOX309
50 BRAKE SYSTEM310
51 STRUCTURE AND FUNCTION 310
GENERAL311
POWER MASTER CYLINDER313
BRAKE 317
PARKING BRAKE319
OPERATION OF PARKING BRAKE320
BRAKE CALIPER321
52 TESTING AND ADJUSTING322
STANDARD VALUE TABLE323
TOOL LIST FOR TESTING AND ADJUSTING324
MEASURING BRAKE PEDAL325
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE326
CHECKING BRAKE PERFORMANCE328
CHECKING BRAKE OIL PRESSURE329
MEASURING WEAR OF BRAKE DISC330
AIR BLEEDING FROM BRAKE CIRCUIT331
CHECKING PARKING BRAKE PERFORMANCE332
CHECKING AND ADJUSTING PARKING BRAKE333
MEASURING CLEARANCE OF PARKING BRAKE334
TROUBLESHOOTING335
TROUBLESHOOTING TABLE336
1BRAKE IS INEFFECTIVE OF NOT VERY EFFECTIVE336
2BRAKE CANNOT BE RELEASED OR DRAGS337
53 DISASSEMBLY AND ASSEMBLY338
POWER MASTER CYLINDER339
REMOVAL339
INSTALLATION340
DISASSEMBLY341
ASSEMBLY344
PARKING BRAKE349
REMOVAL349
INSTALLATION351
PARKING BRAKE PAD353
REMOVAL353
INSTALLATION353
54 MAINTENANCE STANDARD354
POWER MASTER CYLINDER355
BRAKE356
PARKING BRAKE357
60 WORK EQUIPMENT SYSTEM358
61 STRUCTURE AND FUNCTION358
GENERAL359
HYDRAULIC CIRCUIT361
HYDRAULIC CIRCUIT DIAGRAM362
BUCKET LINKAGE363
BUCKET POSITIONER AND BOOM KICK-OUT365
HYDRAULIC TANK367
OIL FILTER BYPASS VALVE368
BREATHER368
MAIN CONTROL VALVE369
RELIEF VALVE371
SAFETY VALVE (WITH SUCTION VALVE)372
SUCTION VALVE373
HYDRAULIC CYLINDER378
HYDRAULIC AND STEERING PUMP379
62 TESTING AND ADJUSTING380
STANDARD VALUE TABLE381
TOOL LIST FOR TESTING AND ADJUSTING382
MEASURING DUMP AND LIFT CONTROL LEVERS383
ADJUSTING DUMP AND LIFT CONTROL LEVERS384
MEASURING THE DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL385
MEASURING HYDRAULIC PRESSURE386
MEASURING LIFT ARM AND BUCKET387
MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET388
ADJUSTING BUCKET POSITIONER389
ADJUSTING BOOM KICK-OUT (OPTION)390
TROUBLESHOOTING 391
TROUBLESHOOTING TABLE392
1LIFT ARM DOES NOT RISE392
2LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER393
3LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT394
4BUCKET CANNOT BE HOLD DOWN WITH LIFT ARM CYLINDER394
5LIFT ARM HAS LARGE HYDRAULIC DRIFT394
6LIFT ARM MOVEMENT IS UNSTEADY DURING WORK394
7LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “RAISE”394
8BUCKET DOES NOT TILT BACK395
9BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER396
10BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK397
11BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER397
12BUCKET HAS LARGE HYDRAULIC DRIFT397
13BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVLES UNDER LOAD397
14BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “TILT BACK”397
15CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY398
63 DISASSEMBLY AND ASSEMBLY399
HYDRAULIC TANK400
REMOVAL400
INSTALLATION402
HYDRAULIC FILTER404
REMOVAL404
INSTALLATION404
HYDRAULIC, STEERING PUMP405
REMOVAL405
INSTALLATION406
MAIN CONTROL VALVE407
REMOVAL407
INSTALLATION409
DISASSEMBLY411
ASSEMBLY411
DUMP CYLINDER413
REMOVAL413
INSTALLATION415
LIFT CYLINDER416
REMOVAL416
INSTALLATION417
DUMP CYLINDER418
DISASSEMBLY418
ASSEMBLY420
LIFT CYLINDER422
DISASSEMBLY422
ASSEMBLY424
WORK EQUIPMENT 427
REMOVAL427
INSTALLATION430
COUNTERWEIGHT433
REMOVAL433
INSTALLATION433
64 MAINTENANCE STANDARD434
MAIN CONTROL VALVE435
DUMP CYLINDER437
LIFT CYLINDER438
BUCKET LINKAGE439
BUCKET POSITIONER AND BOOM KICK-OUT441
BUCKET442
HYDRAULIC AND STEERING PUMP443
80 ELECTRIC AND ELECTRONIC SYSTEM444
81 STRUCTURE AND FUNCTION444
CONTACT SWITCH445
WIRING DIAGRAM449

IMAGES PREVIEW OF THE MANUAL:

S.M 12/12/24