Komatsu WA200-5H Shop Manual
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Komatsu WA200-5H Shop Manual

Komatsu WA200-5H Shop Manual

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MACHINE MODEL
WA200-5H
WA200PT-5H
•
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may re-
quire.
Materials and specifications are subject to change without notice.
•
WA200, 200PT-5 mounts the SAA6D102E-2-A engine.
For details of the engine, see the 102 Series Engine Shop Manual.
© 2004
All Rights Reserved
Printed in Europe 04.2004
SERIAL NUMBER
H50051 and up
H60051 and up
VEBM220100
H
H
00-1

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Summary of Contents for Komatsu WA200-5H

  • Page 1 H60051 and up • This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may re- quire. Materials and specifications are subject to change without notice.
  • Page 2 CONTENTS No. of page 01 GENERAL ........................ 01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ..........10-1 20 TESTING AND ADJUSTING ..............20-1 30 DISASSEMBLY AND ASSEMBLY ............30-1 90 OTHERS ........................90-1 00-2 WA200-5H, WA200PT-5H...

  • Page 3: Important Safety Notice

    Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.

  • Page 4: Safety Notice

    SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi- nal places. 11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts. hydraulic pressure measuring plugs, loosen •...
  • Page 5 FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judge- ments.
  • Page 6 DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be Symbol Item Remarks sent to KOMATSU distributors. Get the most up-to- date information before you start any work. Special safety precautions Safety are necessary when per- forming the work.
  • Page 7 (12) from the fuel injection pump. 9. Remove engine stop solenoid (13) and bracket (14) together. [*3] 3. Disconnect fuel supply hoses (2) and (3). 4. Disconnect fuel filter (4). 5. Disconnect fuel return hose (5). 30-16 WA200-5H, WA200PT-5H...
  • Page 8 15. Remove fuel injection pump nut (22) and washer a Take care not to drop the nut and washer into (23). the case. 16. Using tool A1, disconnect the fuel injection pump shaft and pump drive gear. 30-17 WA200-5H, WA200PT-5H...

  • Page 9: Installation

    19.6 – 29.4 Nm {2.0 – 3.0 kgm} a Install the fuel injection pump assembly according [*5] to the following procedure. 1. Ensure that the drive gear is fixed to the fuel injection timing using timing pin (20). 30-18 WA200-5H, WA200PT-5H...
  • Page 10 4 nuts (25). 3 Fuel injection pump mounting nuts: the timing pin. 3 Fuel injection pump nut temporary tight- 9.8 ± 2 Nm {1.0 ± 0.2 kgm} ening torque: 12.5 ± 2.5 Nm {1.27 ± 0.25 kgm} 30-19 WA200-5H, WA200PT-5H...
  • Page 11 5. Tighten air bleeding plug (29). 3 Air bleeding plug: 7.8 – 11.8 Nm {0.8 – 1.2 kgm} 6. Push the feed pump knob and tighten it. 7. Start the engine, and check that there is no leak from the fuel system. 30-20 WA200-5H, WA200PT-5H...
  • Page 12 3 Spill tube joint bolt: 9 Nm {0.9 kgm} [*3] 3 Nozzle holder: 60 Nm {6.1 kgm} • Bleeding air 4. Loosen and remove nozzle holder assembly (3). Bleed air from the fuel system. See Removal and [*3] installation of fuel injection pump assembly. 30-21 WA200-5H, WA200PT-5H...
  • Page 13 5) Remove air conditioner compressor belt (8). [*1] 6) Remove 2 mounting bolts (4), 2 mounting bolts (5), and air conditioner compressor and a Place the air conditioner piping by the bracket assembly (10). side of the engine without disconnecting 30-22 WA200-5H, WA200PT-5H...

  • Page 14: Cylinder Head

    3) Remove 4 mounting bolts from the inside of rear side a. 4) Raise muffler (23) and disconnect drain tube (24). 7. Disconnect radiator inlet hose (18). [*3] 8. Disconnect aftercooler upper hose (19). [*4] 9. Remove air cleaner and bracket assembly (20). 30-23 WA200-5H, WA200PT-5H...
  • Page 15 2) Remove bracket (27). 12. Remove 6 fuel injection tubes (33). 3) Remove bracket (28). [*7] 4) Remove muffler drain tube mounting bolt (29). 5) Remove exhaust manifold heat insulation cover (30). 6) Remove muffler brackets (31). 30-24 WA200-5H, WA200PT-5H...
  • Page 16 19. Remove engine stop solenoid bracket mounting bolts and nuts (43). [*9] 20. Disconnect air hose (44). [*10] 16. Remove alternator bracket (40). 21. Remove air intake connector (45) and heater (46). 17. Remove engine sling and thermostat housing assembly (41). [*8] 30-25 WA200-5H, WA200PT-5H...
  • Page 17 24. Remove fuel filter (50). a If the nozzle holder is difficult to remove, use tool A3. 25. Disconnect spill hose (51). 26. Disconnect heater hose (52). 29. Remove 6 cylinder head covers (55). [*12] 27. Remove spill tube (53). 30-26 WA200-5H, WA200PT-5H...
  • Page 18 32. Lift off cylinder head assembly (58). 3rd time: Tighten the bolts to 43 ± 6 Nm {4.38 [*15] 4 Cylinder head assembly: 55 kg ± 0.61 kgm} in the order of 1 – 4. 33. Remove cylinder head gasket (59). [*16] 30-27 WA200-5H, WA200PT-5H...
  • Page 19 1. Set cylinder head gasket (59) to the cylinder a Check that the gasket is matched to the hole block. of the block. 2. Sling cylinder head assembly (58) and set it to the cylinder block. 30-28 WA200-5H, WA200PT-5H...
  • Page 20 Ensure that the ball of the adjustment screw mounting bolts with fingers. a Lubricate the thread portion and seat surface is fitted to the socket of push rod (57). of bolts with 8 mm diameter and bolts with 12 mm diameter with engine oil. 30-29 WA200-5H, WA200PT-5H...

  • Page 21: Removal And Installation Of Engine

    1) Remove left and right fenders (1). cab. 2) Remove covers (2), (3), and (4). 7) Disconnect the 2 window washer hoses (9) at 3) Remove pre-cleaner (5). the right front of the engine hood. [*1] 4) Remove cover (6). 30-30 WA200-5H, WA200PT-5H...
  • Page 22 With the air conditioner piping connected, bolts (13), 2 pieces on each side. move the air conditioner condenser to the engine and fix it with a rope or some- thing. 14) Remove grille (17), and remove fan guard (18). 30-31 WA200-5H, WA200PT-5H...
  • Page 23 Download the full PDF manual instantly. Our customer service e-mail: aservicemanualpdf@yahoo.com...

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