Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU WA200-1 SHOP MANUAL SEBM0418C102 – PDF DOWNLOAD
$30.95
KOMATSU WA200-1 SHOP MANUAL SEBM0418C102 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU WA200-1 SHOP MANUAL SEBM0418C102 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA200-1 SHOP MANUAL SEBM0418C102 – PDF DOWNLOAD
Language : English
Pages : 449
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA200-1 SHOP MANUAL SEBM0418C102 – PDF DOWNLOAD
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 SPEED....................................................................100 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION.....................................102 MEASURING SHIFT LEVER...........................................................................104 MEASURING VALVE SPOOL OPERATING FORCE AND TRAVEL................................................105 TIRE AND WHEEL..................................................................................107 TROUBLESHOOTING.................................................................................108 PRECAUTIONS WHEN TROUBLESHOOTING............................................................109 METHOD OF READING TROUBLESHOOTING TABLE.....................................................111 PREVENTING RECURRENCE OF TROUBLE............................................................113 TROUBLESHOOTING TABLE.......................................................................114 1.MACHINE DOES NOT MOVE OFF.............................................................114 2.MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF..........................116 3.LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR..........................................118 4.LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR.......................................119 5.OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH...........................................120 23 DISASSEMBLY AND ASSEMBLY.........................................................................121 TORQUE CONVERTER CHARGING PUMP..................................................................122 REMOVAL.....................................................................................122 INSTALLATION................................................................................122 TORQUE CONVERTER, TRANSMISSION..................................................................123 REMOVAL.....................................................................................123 INSTALLATION................................................................................129 TORQUE CONVERTER................................................................................135 DISASSEMBLY.................................................................................135 ASSEMBLY....................................................................................138 TRANSMISSION....................................................................................141 DISASSEMBLY.................................................................................141 ASSEMBLY....................................................................................148 CLUTCH PACK.....................................................................................157 DISASSEMBLY.................................................................................157 ASSEMBLY....................................................................................163 TRANSMISSION CONTROL VALVE......................................................................176 REMOVAL.....................................................................................176 INSTALLATION................................................................................177 DISASSEMBLY.................................................................................179 ASSEMBLY....................................................................................179 MECHANICAL VALVE................................................................................181 DISASSEMBLY.................................................................................181 ASSEMBLY....................................................................................182 DRIVE SHAFT.....................................................................................183 DISASSEMBLY.................................................................................183 ASSEMBLY....................................................................................185 FRONT AXLE......................................................................................187 REMOVAL.....................................................................................187 INSTALLATION................................................................................189 REAR AXLE.......................................................................................191 REMOVAL.....................................................................................191 INSTALLATION................................................................................195 DIFFERENTIAL....................................................................................200 DISASSEMBLY.................................................................................200 ASSEMBLY....................................................................................204 AXLE HOUSING....................................................................................214 DISASSEMBLY.................................................................................214 ASSEMBLY....................................................................................218 24 MAINTENANCE STANDARD.............................................................................224 TRANSMISSION AND ENGINE MOUNT...................................................................225 TORQUE CONVERTER CHARGING PUMP..................................................................226 TORQUE CONVERTER ..............................................................................227 TORQUE CONVERTER REGULATOR VALVE................................................................228 TRANSMISSION ..................................................................................229 TRANSMISSION CLUTCH ASSEMBLY....................................................................231 TRANSMISSION CONTROL VALVE......................................................................233 UPPER VALVE.................................................................................233 LOWER VALVE.................................................................................235 SELECTOR VALVE..............................................................................236 AXLE............................................................................................237 DIFFERENTIAL....................................................................................239 FINAL DRIVE.....................................................................................241 DRIVE SHAFT.....................................................................................242 AXLE MOUNT......................................................................................243 40 STEERING SYSTEM......................................................................................244 41 STRUCTURE AND FUNCTION...........................................................................244 GENERAL.........................................................................................245 HYDRAULIC CIRCUIT FOR STEERING..................................................................247 HYDRAULIC CIRCUIT DIAGRAM FOR STEERING......................................................248 OPERATION OF STEERING VALVE.................................................................249 TWO-WAY RESTRICTOR VALVE........................................................................250 STEERING VALVE..................................................................................251 STEERING RELIEF VALVE.......................................................................253 SAFETY VALVE (WITH SUCTION VALVE)...........................................................254 OPERATION OF DEMAND VALVE...................................................................255 STEERING COLUMN AND GEAR BOX....................................................................257 STEERING LINKAGE................................................................................258 STEERING CYLINDER...............................................................................259 CENTER HINGE PIN................................................................................260 42 TESTING AND ADJUSTING ...........................................................................261 STANDARD VALUE TABLE............................................................................262 TOOL LIST FOR TESTING AND ADJUSTING.............................................................262 MEASURING STEERING WHEEL PLAY...................................................................263 MEASURING OPERATING FORCE OF STEERING WHEEL.....................................................264 OPERATING TIME OF STEERING WHEEL................................................................265 TESTING STEERING LINKAGE........................................................................266 ADJUSTING STEERING LINKAGE......................................................................267 STEERING OIL PRESSURE...........................................................................268 TROUBLESHOOTING.................................................................................269 TROUBLESHOOTING TABLE.......................................................................270 1.STEERING WHEEL DOES NOT TURN..........................................................270 2.STEERING WHEEL IS SLUGGISH............................................................271 3.STEERING WHEEL MOVE UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.........................272 4.MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING............272 5.LEFT AND RIGHT TURNING RADIUS ARE DIFFERENT...........................................272 43 DISASSEMBLY AND ASSEMBLY.........................................................................273 STEERING GEAR BOX...............................................................................274 REMOVAL.....................................................................................274 INSTALLATION................................................................................275 DISASSEMBLY.................................................................................276 ASSEMBLY....................................................................................277 STEERING VALVE..................................................................................279 REMOVAL.....................................................................................279 INSTALLATION................................................................................281 DISASSEMBLY.................................................................................283 ASSEMBLY....................................................................................283 STEERING CYLINDER...............................................................................285 REMOVAL.....................................................................................285 INSTALLATION................................................................................286 DISASSEMBLY.................................................................................287 ASSEMBLY....................................................................................289 CENTER HINGE PIN................................................................................292 REMOVAL.....................................................................................292 INSTALLATION................................................................................297 44 MAINTENANCE STANDARD.............................................................................302 STEERING VALVE..................................................................................303 STEERING CYLINDER MOUNT.........................................................................304 STEERING CYLINDER .............................................................................305 STEERING LINKAGE................................................................................306 CENTER HINGE PIN................................................................................307 STEERING COLUMN AND GEAR BOX....................................................................309 50 BRAKE SYSTEM.........................................................................................310 51 STRUCTURE AND FUNCTION ..........................................................................310 GENERAL.........................................................................................311 POWER MASTER CYLINDER...........................................................................313 BRAKE .........................................................................................317 PARKING BRAKE...................................................................................319 OPERATION OF PARKING BRAKE..................................................................320 BRAKE CALIPER...............................................................................321 52 TESTING AND ADJUSTING............................................................................322 STANDARD VALUE TABLE............................................................................323 TOOL LIST FOR TESTING AND ADJUSTING.............................................................324 MEASURING BRAKE PEDAL...........................................................................325 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.......................................................326 CHECKING BRAKE PERFORMANCE......................................................................328 CHECKING BRAKE OIL PRESSURE.....................................................................329 MEASURING WEAR OF BRAKE DISC....................................................................330 AIR BLEEDING FROM BRAKE CIRCUIT.................................................................331 CHECKING PARKING BRAKE PERFORMANCE..............................................................332 CHECKING AND ADJUSTING PARKING BRAKE............................................................333 MEASURING CLEARANCE OF PARKING BRAKE............................................................334 TROUBLESHOOTING.................................................................................335 TROUBLESHOOTING TABLE.......................................................................336 1.BRAKE IS INEFFECTIVE OF NOT VERY EFFECTIVE............................................336 2.BRAKE CANNOT BE RELEASED OR DRAGS.....................................................337 53 DISASSEMBLY AND ASSEMBLY.........................................................................338 POWER MASTER CYLINDER...........................................................................339 REMOVAL.....................................................................................339 INSTALLATION................................................................................340 DISASSEMBLY.................................................................................341 ASSEMBLY....................................................................................344 PARKING BRAKE...................................................................................349 REMOVAL.....................................................................................349 INSTALLATION................................................................................351 PARKING BRAKE PAD...............................................................................353 REMOVAL.....................................................................................353 INSTALLATION................................................................................353 54 MAINTENANCE STANDARD.............................................................................354 POWER MASTER CYLINDER...........................................................................355 BRAKE...........................................................................................356 PARKING BRAKE...................................................................................357 60 WORK EQUIPMENT SYSTEM................................................................................358 61 STRUCTURE AND FUNCTION...........................................................................358 GENERAL.........................................................................................359 HYDRAULIC CIRCUIT...............................................................................361 HYDRAULIC CIRCUIT DIAGRAM.......................................................................362 BUCKET LINKAGE..................................................................................363 BUCKET POSITIONER AND BOOM KICK-OUT.............................................................365 HYDRAULIC TANK..................................................................................367 OIL FILTER BYPASS VALVE.....................................................................368 BREATHER....................................................................................368 MAIN CONTROL VALVE..............................................................................369 RELIEF VALVE................................................................................371 SAFETY VALVE (WITH SUCTION VALVE)...........................................................372 SUCTION VALVE...............................................................................373 HYDRAULIC CYLINDER..............................................................................378 HYDRAULIC AND STEERING PUMP.....................................................................379 62 TESTING AND ADJUSTING............................................................................380 STANDARD VALUE TABLE............................................................................381 TOOL LIST FOR TESTING AND ADJUSTING.............................................................382 MEASURING DUMP AND LIFT CONTROL LEVERS..........................................................383 ADJUSTING DUMP AND LIFT CONTROL LEVERS..........................................................384 MEASURING THE DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL..........................................385 MEASURING HYDRAULIC PRESSURE....................................................................386 MEASURING LIFT ARM AND BUCKET...................................................................387 MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET................................................388 ADJUSTING BUCKET POSITIONER.....................................................................389 ADJUSTING BOOM KICK-OUT (OPTION)................................................................390 TROUBLESHOOTING ................................................................................391 TROUBLESHOOTING TABLE.......................................................................392 1.LIFT ARM DOES NOT RISE................................................................392 2.LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER.......................393 3.LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT......................394 4.BUCKET CANNOT BE HOLD DOWN WITH LIFT ARM CYLINDER.....................................394 5.LIFT ARM HAS LARGE HYDRAULIC DRIFT....................................................394 6.LIFT ARM MOVEMENT IS UNSTEADY DURING WORK.............................................394 7.LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"....394 8.BUCKET DOES NOT TILT BACK.............................................................395 9.BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...............................396 10.BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK........................................397 11.BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER....................................397 12.BUCKET HAS LARGE HYDRAULIC DRIFT.....................................................397 13.BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVLES UNDER LOAD..............................397 14.BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"....397 15.CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY....................398 63 DISASSEMBLY AND ASSEMBLY.........................................................................399 HYDRAULIC TANK..................................................................................400 REMOVAL.....................................................................................400 INSTALLATION................................................................................402 HYDRAULIC FILTER................................................................................404 REMOVAL.....................................................................................404 INSTALLATION................................................................................404 HYDRAULIC, STEERING PUMP........................................................................405 REMOVAL.....................................................................................405 INSTALLATION................................................................................406 MAIN CONTROL VALVE..............................................................................407 REMOVAL.....................................................................................407 INSTALLATION................................................................................409 DISASSEMBLY.................................................................................411 ASSEMBLY....................................................................................411 DUMP CYLINDER...................................................................................413 REMOVAL.....................................................................................413 INSTALLATION................................................................................415 LIFT CYLINDER...................................................................................416 REMOVAL.....................................................................................416 INSTALLATION................................................................................417 DUMP CYLINDER...................................................................................418 DISASSEMBLY.................................................................................418 ASSEMBLY....................................................................................420 LIFT CYLINDER...................................................................................422 DISASSEMBLY.................................................................................422 ASSEMBLY....................................................................................424 WORK EQUIPMENT ................................................................................427 REMOVAL.....................................................................................427 INSTALLATION................................................................................430 COUNTERWEIGHT...................................................................................433 REMOVAL.....................................................................................433 INSTALLATION................................................................................433 64 MAINTENANCE STANDARD.............................................................................434 MAIN CONTROL VALVE..............................................................................435 DUMP CYLINDER...................................................................................437 LIFT CYLINDER...................................................................................438 BUCKET LINKAGE..................................................................................439 BUCKET POSITIONER AND BOOM KICK-OUT.............................................................441 BUCKET..........................................................................................442 HYDRAULIC AND STEERING PUMP.....................................................................443 80 ELECTRIC AND ELECTRONIC SYSTEM.......................................................................444 81 STRUCTURE AND FUNCTION...........................................................................444 CONTACT SWITCH..................................................................................445 WIRING DIAGRAM..................................................................................449
S.S 21/12/24
