Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-03 PDF – Serial 85001 and Up
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Complete Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-03 covering serial numbers 85001 and up. Includes engine, HST, hydraulics, brakes, steering, electrical, troubleshooting, disassembly, and circuit diagrams.
Description
The Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-03 is the complete workshop reference for the WA200-8 wheel loader, covering machines from serial number 85001 onward. Across thousands of pages, this manual documents the SAA4D107E-3 diesel engine, the HST hydrostatic transmission system, transfer and axles, wet multiple-disc brakes, articulated steering, the full hydraulic circuit, the electronic control network, and the urea SCR aftertreatment system introduced for Tier 4 Final and Stage IV compliance. Whether you are diagnosing a fault code, rebuilding a hydraulic cylinder, setting valve clearances, or tracing a wiring harness, this Komatsu WA200-8 shop manual provides the specifications and step-by-step procedures to do the job correctly.
File Details
- Manual type: Shop Manual
- Brand: Komatsu
- Model: WA200-8 Wheel Loader
- Serial numbers: 85001 and up
- Document number: SEN06627-03
- Engine: Komatsu SAA4D107E-3 diesel engine
- Language: English
- File format: PDF
Chapters Covered
- 00 Index and Foreword β Abbreviation list, safety notices, fire precautions, waste disposal, exhaust gas regulations, DEF handling and storage, hydraulic equipment handling, piping disconnection and connection, electrical equipment handling, fuel and intake system handling, KOMTRAX, push-pull couplers, connector types, electrical wire codes, tightening torque table, conversion table.
- 01 Specifications β Specifications, specification drawing, weight table, and fuel, coolant, and lubricants tables for North America and the European Union.
- 10 Structure and Function β Urea SCR system, boot-up system, system operating lamp, battery disconnect switch, preheating system, engine system and engine control, automatic idle stop, damper, VGT, EGR system, KCCV system, KDOC, cooling system and cooling fan control, machine monitor, rearview monitor, KOMTRAX, control system components, hydraulic system, power train system, HST control, charge, and pump control, KTCS, axle, undercarriage and frame, tire, work equipment, cab.
- 20 Standard Value Table β Engine standard values, machine standard values, and machine posture and procedure for measuring performance.
- 30 Testing and Adjusting β Tools for testing and adjusting, engine and cooling system tests (engine speed, boost pressure, exhaust gas color, valve clearance, compression pressure, blowby pressure, engine oil pressure, fuel pressure, fuel discharge, return and leakage, air bleeding), power train tests, steering system tests, brake system tests and adjustments, hydraulic system tests, work equipment, cab and attachments, electrical system settings, and Pm Clinic.
- 40 Troubleshooting β General troubleshooting points, urea SCR troubleshooting, checks before troubleshooting, inspection procedures, electrical system troubleshooting preparation, symptom and troubleshooting numbers, connectors list and layout, connector contact identification, T-branch box and adapter table, fuse location table, KDOC replacement precautions, harness checker procedures, failure codes table, troubleshooting by failure code, E-mode, H-mode, and S-mode.
- 50 Disassembly and Assembly β Engine and cooling system, power train, undercarriage and frame, hydraulic system, work equipment, cab and attachments, and electrical system.
- 60 Maintenance Standard β Engine and cooling system, power train, steering system, brake system, undercarriage and frame, and hydraulic system.
- 80 The Other Information β Air conditioner structure and function, troubleshooting for blower motor system, fresh and recirc air changeover, troubleshooting using gauge pressure, connection of service tool, and compressor oil handling.
- 90 Circuit Diagrams β Hydraulic circuit diagram and symbols, electrical circuit diagram and symbols, machine electrical circuit diagrams (1/10 through 10/10), floor electrical circuit diagrams (1/9 through 9/9), and index.
What sets this Komatsu WA200-8 shop manual apart is the way the chapters build on each other. Structure and function explanations feed into testing and adjusting procedures, which in turn feed into disassembly and assembly steps and troubleshooting pathways. The troubleshooting chapter alone runs to hundreds of pages of failure code descriptions, E-mode symptom tables, H-mode hydraulic and mechanical diagnostics, and S-mode engine diagnostics. The circuit diagram chapter provides complete hydraulic and electrical schematics with connector pin identification, making it possible to trace circuits and isolate faults without guesswork.
Systems and Procedures Covered
Engine coverage includes the SAA4D107E-3 common rail diesel with VGT, cooled EGR, KCCV, and KDOC and SCR aftertreatment. Power train coverage includes the HST pump and motors, transfer with clutch and parking brake, front and rear axles with torque proportioning or limited slip differentials, and final drives. Brake coverage includes the wet multiple-disc wheel brakes, slack adjusters, parking brake, and accumulator charge circuit. Steering coverage includes the Orbitrol, priority valve, cushion valve, and steering cylinders. Hydraulic coverage includes the control valve, PPC valves, ECSS, and the full circuit diagram. Electrical coverage includes the engine controller, HST controller, monitor controller, machine monitor, KOMTRAX terminal, CAN and LIN networks, and all major sensors and actuators.
Using This Manual in the Workshop
Because the WA200-8 combines hydrostatic drive, electronic control, and exhaust aftertreatment, incorrect procedures or specifications can lead to repeat failures or expensive damage. This manual gives you the correct torque values, pressure settings, clearances, and diagnostic steps for each system. The testing and adjusting chapter provides the standard values and repair limits needed to judge whether a component is within specification, while the maintenance standard chapter gives the criteria for disassembly and assembly. The troubleshooting chapters are organized by failure code and by symptom, so you can move from a reported problem to the affected circuit or component methodically.
Complete Bookmarks
The complete bookmarks in the βKomatsu WA200-8 Wheel Loader Shop Manual SEN06627-03 PDF – Serial 85001 and Upβ are as follows:
+00 INDEX AND FOREWORDp. 3
+FOREWORD, SAFETY, BASIC INFORMATIONp. 27
+PRECAUTIONS FOR DEFp. 42
+DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLERp. 59
+01 SPECIFICATIONSp. 93
+SPECIFICATIONSp. 101
+SPECIFICATION DRAWINGp. 101
+SPECIFICATIONSp. 103
+WEIGHT TABLEp. 109
+FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)p. 111
+FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)p. 113
+10 STRUCTURE AND FUNCTIONp. 115
+UREA SCR SYSTEMp. 126
+FUNCTION OF UREA SCR SYSTEMp. 129
+COMPONENT PARTS OF UREA SCR SYSTEMp. 146
+BOOT-UP SYSTEMp. 155
+SYSTEM OPERATING LAMP SYSTEMp. 157
+BATTERY DISCONNECT SWITCHp. 158
+PREHEATING SYSTEMp. 159
+ENGINE SYSTEMp. 161
+LAYOUT DRAWING OF ENGINE SYSTEMp. 161
+ENGINE CONTROL SYSTEMp. 163
+AUTOMATIC IDLE STOP SYSTEMp. 170
+COMPONENT PARTS OF ENGINE SYSTEMp. 171
+COOLING SYSTEMp. 188
+LAYOUT DRAWING OF COOLING SYSTEMp. 188
+COOLING FAN CONTROL SYSTEMp. 190
+COMPONENT PARTS OF COOLING SYSTEMp. 195
+CONTROL SYSTEMp. 206
+MACHINE MONITOR SYSTEMp. 208
+REARVIEW MONITOR SYSTEMp. 210
+KOMTRAX SYSTEMp. 211
+COMPONENT PARTS OF CONTROL SYSTEMp. 212
+HYDRAULIC SYSTEMp. 254
+COMPONENT PARTS OF HYDRAULIC SYSTEMp. 255
+POWER TRAIN SYSTEMp. 281
+HST CONTROL SYSTEMp. 286
+HST CHARGE SYSTEMp. 288
+HST PUMP CONTROL SYSTEMp. 289
+HST CONTROLLER GEAR SHIFT CONTROL FUNCTIONp. 291
+HST SYSTEM PROTECTION FUNCTIONp. 295
+KOMATSU TRACTION CONTROL SYSTEM (KTCS)p. 297
+COMPONENT PARTS OF POWER TRAIN SYSTEMp. 301
+WORK EQUIPMENT SYSTEMp. 346
+WORK EQUIPMENT CONTROL SYSTEMp. 348
+WORK EQUIPMENT LOCK SYSTEMp. 349
+BUCKET POSITIONER SYSTEMp. 351
+BOOM KICK-OUT SYSTEMp. 354
+ECSSp. 357
+COMPONENT PARTS OF WORK EQUIPMENT SYSTEMp. 359
+STEERING SYSTEMp. 371
+STEERING COLUMNp. 372
+COMPONENT PARTS OF STEERING SYSTEMp. 373
+BRAKE SYSTEMp. 389
+PARKING BRAKE CONTROL SYSTEMp. 391
+COMPONENT PARTS OF BRAKE SYSTEMp. 394
+UNDERCARRIAGE AND FRAMEp. 413
+FRAME, AXLE MOUNT AND CENTER HINGE PINp. 413
+TIREp. 416
+WORK EQUIPMENTp. 418
+CAB AND ITS ATTACHMENTSp. 420
+ROPS CABp. 420
+CAB MOUNTp. 421
+20 STANDARD VALUE TABLEp. 423
+STANDARD VALUE TABLE FOR ENGINEp. 431
+STANDARD VALUE TABLE FOR MACHINEp. 436
+30 TESTING AND ADJUSTINGp. 451
+RELATED INFORMATION ON TESTING AND ADJUSTINGp. 461
+ENGINE AND COOLING SYSTEMp. 469
+TEST ENGINE SPEEDp. 469
+TEST BOOST PRESSUREp. 472
+TEST EXHAUST GAS COLORp. 475
+TEST AND ADJUST VALVE CLEARANCEp. 478
+TEST COMPRESSION PRESSUREp. 481
+TEST BLOWBY PRESSUREp. 486
+TEST ENGINE OIL PRESSUREp. 489
+TEST FUEL PRESSUREp. 491
+TEST FUEL DISCHARGE, RETURN AND LEAKAGEp. 496
+BLEED AIR FROM FUEL SYSTEMp. 502
+TEST FUEL CIRCUIT FOR LEAKAGEp. 504
+TEST KDOC, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGEp. 508
+TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDSp. 509
+TEST ENGINE PIPING FOR DAMAGE AND LOOSENESSp. 510
+TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSIONp. 511
+TEST ALTERNATOR BELTp. 513
+TEST AUTOMATIC TENSIONERp. 515
+TEST SCR RELATED FUNCTIONSp. 518
+CLEAN AdBlue/DEF TANKp. 550
+POWER TRAINp. 555
+TEST AND ADJUST HST OIL PRESSUREp. 555
+TEST THE CONTROL PRESSURE OF TRANSFER CLUTCHp. 560
+TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGEp. 562
+STEERING SYSTEMp. 563
+TEST STEERING WHEELp. 563
+TEST AND ADJUST STEERING CIRCUIT OIL PRESSUREp. 565
+BLEED AIR FROM STEERING CYLINDER CIRCUITp. 568
+BRAKE SYSTEMp. 569
+RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUITp. 569
+TEST WHEEL BRAKE OIL PRESSUREp. 570
+TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSUREp. 572
+BLEED AIR FROM BRAKE CIRCUITp. 574
+TEST BRAKING PERFORMANCEp. 575
+TEST BRAKE PEDALp. 576
+TEST AND ADJUST BRAKE PEDAL AND LINKAGEp. 577
+TEST LOWERING OF WHEEL BRAKE PRESSUREp. 578
+TEST WEAR OF WHEEL BRAKE DISCp. 581
+TEST PARKING BRAKE OIL PRESSUREp. 583
+TEST PARKING BRAKE PERFORMANCEp. 585
+RELEASE PARKING BRAKE MANUALLYp. 586
+HYDRAULIC SYSTEMp. 587
+RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUITp. 587
+TEST AND ADJUST WORK EQUIPMENT OIL PRESSUREp. 589
+TEST WORK EQUIPMENT PPC OIL PRESSUREp. 592
+BLEED AIR FROM WORK EQUIPMENT PPC CIRCUITp. 594
+TEST COOLING FAN SPEEDp. 595
+TEST COOLING FAN CIRCUIT OIL PRESSUREp. 596
+BLEED AIR FROM COOLING FAN CIRCUITp. 598
+TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GASp. 600
+WORK EQUIPMENTp. 605
+TEST AND ADJUST BUCKET POSITIONERp. 605
+CAB AND ITS ATTACHMENTSp. 607
+TEST DIRECTIONAL LEVERp. 607
+TEST MULTIFUNCTION MONO-LEVERp. 608
+TEST ACCELERATOR PEDALp. 610
+ELECTRICAL SYSTEMp. 612
+SET AND OPERATE MACHINE MONITORp. 614
+ADJUST REARVIEW CAMERA ANGLEp. 711
+TEST DIODESp. 715
+Pm CLINICp. 716
+Pm CLINIC SERVICEp. 716
+40 TROUBLESHOOTINGp. 727
+RELATED INFORMATION ON TROUBLESHOOTINGp. 744
+INSPECTION PROCEDURE BEFORE TROUBLESHOOTINGp. 761
+TESTING IN ACCORDANCE WITH TESTING PROCEDUREp. 763
+TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)p. 900
+TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)p. 1688
+TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)p. 1835
+TROUBLESHOOTING OF ENGINE (S-MODE)p. 1899
+50 DISASSEMBLY AND ASSEMBLYp. 1935
+RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLYp. 1946
+ENGINE AND COOLING SYSTEMp. 1982
+REMOVE AND INSTALL SUPPLY PUMP ASSEMBLYp. 1982
+REMOVE AND INSTALL INJECTOR ASSEMBLYp. 1995
+REMOVE AND INSTALL CYLINDER HEAD ASSEMBLYp. 2018
+REMOVE AND INSTALL EGR VALVE ASSEMBLYp. 2065
+REMOVE AND INSTALL EGR COOLER ASSEMBLYp. 2072
+REMOVE AND INSTALL STARTING MOTOR ASSEMBLYp. 2087
+REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELTp. 2091
+REMOVE AND INSTALL ALTERNATOR BELTp. 2095
+REMOVE AND INSTALL ALTERNATOR ASSEMBLYp. 2104
+REMOVE AND INSTALL AUTOMATIC TENSIONERp. 2108
+REMOVE AND INSTALL RADIATOR ASSEMBLYp. 2118
+REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLYp. 2131
+REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLYp. 2140
+REMOVE AND INSTALL AFTERCOOLER ASSEMBLYp. 2144
+REMOVE AND INSTALL ENGINE ASSEMBLYp. 2149
+REMOVE AND INSTALL ENGINE FRONT OIL SEALp. 2188
+REMOVE AND INSTALL ENGINE REAR OIL SEALp. 2200
+REMOVE AND INSTALL ENGINE HOOD ASSEMBLYp. 2207
+REMOVE AND INSTALL KDOC ASSEMBLYp. 2231
+REMOVE AND INSTALL KDOC AND SCR ASSEMBLYp. 2248
+REMOVE AND INSTALL BELLOWS PIPE ASSEMBLYp. 2272
+REMOVE AND INSTALL FUEL TANK ASSEMBLYp. 2282
+REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLYp. 2291
+REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLYp. 2307
+REMOVE AND INSTALL AdBlue/DEF TANK SENSORp. 2312
+REMOVE AND INSTALL AdBlue/DEF TANK STRAINERp. 2320
+REMOVE AND INSTALL SCR ASSEMBLYp. 2322
+REMOVE AND INSTALL KCCV ASSEMBLYp. 2343
+REMOVE AND INSTALL VGT ASSEMBLYp. 2347
+REMOVE AND INSTALL AdBlue/DEF MIXING TUBEp. 2378
+REMOVE AND INSTALL AdBlue/DEF INJECTORp. 2391
+REMOVE AND INSTALL AdBlue/DEF PUMPp. 2397
+REMOVE AND INSTALL AdBlue/DEF HOSEp. 2406
+REMOVE AND INSTALL AIR CLEANER ASSEMBLYp. 2427
+REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLYp. 2435
+REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLYp. 2442
+POWER TRAINp. 2446
+REMOVE AND INSTALL HST PUMP ASSEMBLY, STEERING, WORK EQUIPMENT, BRAKE AND COOLING FAN, AND TRANSFER LUBRICATION PUMP ASSEMBLYp. 2446
+REMOVE AND INSTALL HST MOTOR1 ASSEMBLYp. 2455
+REMOVE AND INSTALL HST MOTOR2 ASSEMBLYp. 2460
+REMOVE AND INSTALL TRANSFER ASSEMBLYp. 2464
+DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLYp. 2479
+REMOVE AND INSTALL FRONT AXLE ASSEMBLYp. 2514
+REMOVE AND INSTALL REAR AXLE ASSEMBLYp. 2518
+DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLYp. 2523
+DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLYp. 2536
+UNDERCARRIAGE AND FRAMEp. 2573
+REMOVE AND INSTALL CENTER HINGE PINp. 2573
+REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLYp. 2594
+HYDRAULIC SYSTEMp. 2619
+REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLYp. 2619
+REMOVE AND INSTALL CONTROL VALVE ASSEMBLYp. 2632
+DISASSEMBLE AND ASSEMBLE HYDRAULIC CYLINDER ASSEMBLYp. 2642
+WORK EQUIPMENTp. 2653
+REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLYp. 2653
+CAB AND ITS ATTACHMENTSp. 2669
+REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLYp. 2669
+REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)p. 2695
+REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLYp. 2705
+REMOVE AND INSTALL OPERATOR'S SEAT ASSEMBLYp. 2718
+REMOVE AND INSTALL SEAT BELTp. 2720
+ELECTRICAL SYSTEMp. 2722
+REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLYp. 2722
+REMOVE AND INSTALL HST CONTROLLER ASSEMBLYp. 2731
+REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLYp. 2735
+REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLYp. 2738
+REMOVE AND INSTALL MACHINE MONITOR ASSEMBLYp. 2743
+REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSORp. 2749
+REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSORp. 2752
+REMOVE AND INSTALL SCR TEMPERATURE SENSORp. 2755
+REMOVE AND INSTALL SCR OUTLET NOx SENSORp. 2762
+REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLYp. 2769
+60 MAINTENANCE STANDARDp. 2771
+ENGINE AND COOLING SYSTEMp. 2779
+POWER TRAINp. 2785
+STEERING SYSTEMp. 2808
+BRAKE SYSTEMp. 2813
+UNDERCARRIAGE AND FRAMEp. 2818
+HYDRAULIC SYSTEMp. 2823
+WORK EQUIPMENTp. 2832
+CAB AND ITS ATTACHMENTSp. 2839
+80 APPENDIXp. 2841
+AIR CONDITIONER SYSTEMp. 2850
+COMPONENT PARTS OF AIR CONDITIONER SYSTEMp. 2857
+AIR CONDITIONER UNITp. 2857
+COMPONENT PARTS OF AIR CONDITIONER UNITp. 2859
+AIR CONDITIONER CONTROLLERp. 2862
+COMPRESSORp. 2863
+CONDENSERp. 2864
+RECEIVER DRIERp. 2865
+SENSORS FOR AIR CONDITIONER SYSTEMp. 2866
+AIR CONDITIONER SYSTEM DIAGRAMp. 2872
+INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLERp. 2873
+CHECK TEMPERATURE CONTROL FUNCTIONp. 2883
+TEST VENT (MODE) CHANGEOVERp. 2885
+TESTING FRESH/RECIRC AIR CHANGEOVERp. 2887
+TEST RELAYSp. 2891
+CONNECTION OF SERVICE TOOLp. 2928
+90 CIRCUIT DIAGRAMSp. 2935
+HYDRAULIC CIRCUIT DIAGRAMp. 2943
+ELECTRICAL CIRCUIT DIAGRAMp. 2948
Delivery and Format
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The Komatsu WA200-8 Wheel Loader Shop Manual SEN06627-03 is delivered as an instant PDF download after payment. There is no shipping and no waiting for a physical book β the file can be viewed on any device and printed for use in the workshop. Whether you are a technician, fleet owner, or operator maintaining a WA200-8, this manual gives you the information needed to keep the machine running correctly.
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