These Komatsu WA200-6 and WA200PZ-6 wheel loaders are mid-size machines used for loading trucks, stockpiling, and general yard work. The Komatsu WA200-6, WA200PZ-6 Wheel Loader Shop Manual (SEN05282-13) is what shop techs and field mechanics reach for when a simple operator’s manual won’t cut it. People usually use this kind of book when a fault code won’t clear, a system needs teardown, or a major component has to come out and go back in correctly.
What this manual helps you do
- Trace hydraulic and electrical faults on WA200-6 and WA200PZ-6 using factory-style diagnostic flows and wiring information.
- Check removal and installation sequences for major components so you don’t miss hidden fasteners or damage hoses and harnesses.
- Follow step‑by‑step repair procedures for engine, transmission, axles, steering, and brakes as used in a workshop environment.
- Diagnose sensor and control issues in the loader’s electronic systems using the kind of logic most shops teach new techs.
- Verify adjustments and post-repair checks that prevent common student mistakes like misrouted lines or misaligned linkages.
Who this is for
This shop manual is aimed at field technicians, shop mechanics, and serious trainees who are doing real repairs on Komatsu WA200-6 or WA200PZ-6 loaders. If you just need basic operation, daily checks, or safety info, you’d be better off with the Operation & Maintenance manual instead of this one.
FAQ
Q: Is this a PDF I can search and print?
A: Yes, it’s a digital PDF you can search on-screen and print pages you want to take to the machine.
Q: Is it detailed enough for full overhauls?
A: It’s built for workshop-level repair, so you get the kind of teardown and reassembly procedures a dealer shop would follow.
Q: How do I know if it matches my serial number or variant?
A: Check your loader’s plate against the SEN05282-13 reference; if your machine is listed there by your seller, this is the right shop manual.
Bottom line: If you’re actually wrenching on a WA200-6 or WA200PZ-6 and need factory-style repair guidance, this is the right manual; if you’re just operating the machine, keep looking for the operator’s book instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- 100 Index
- Composition of shop manual
- Table of contents
- 200 Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic component
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out operation
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- Conversion table
- 01 Specification
- 100 Specification and technical data
- Specification dimension drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
- 10 Structure, function and maintenance standard
- 100 Engine and cooling system
- Engine mount and transfer mount
- Damper
- Cooling system
- Cooling system hydraulic piping diagram
- Cooling fan motor
- 200 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
- 300 Steering system
- Steering piping diagram
- Steering column
- Priority valve
- Orbit-roll valve
- 2-way restrictor valve
- Cushion valve
- Steering cylinder
- Emergency steering piping diagram
- Emergency steering valve
- Steering relief valve
- 400 Brake system
- Brake piping diagram
- Charge valve
- Brake valve
- Inching valve
- Accumulator (for brake)
- Slack adjuster
- Brake
- Parking brake control
- Parking brake
- 500 Undercarriage and frame
- Axle mount and center hinge pin
- Tires
- 600 Hydraulic system
- Work equipment hydraulic piping diagram
- Work equipment control lever linkage
- Hydraulic tank
- 4-gear pump
- Work equipment control valve
- PPC valve
- Lock valve
- Accumulator (for PPC circuit)
- Bypass valve
- Quick coupler solenoid valve
- ECSS valve
- Accumulator (for ECSS)
- 700 Work equipment
- Work equipment linkage
- Bucket
- Bucket positioner and boom kick-out
- Work equipment cylinder
- 800 Cab and its attachments
- 901 Electrical system, Part 1
- Machine monitor system
- Machine monitor
- Rearview monitor system
- 902 Electrical system, Part 2
- Electrical system (HST controller system)
- HST controller
- ECSS system
- KOMTRAX system
- Engine starting circuit
- Engine stopping circuit
- Preheating circuit
- Engine output derating function
- Automatic warm-up function
- Parking brake circuit
- Coupler plunger control system
- Max. traction switch
- Multi-function knob
- Sensor
- 20 Standard value table
- 100 Standard service value table
- Standard service value table for engine
- Standard service value table for chassis
- 30 Testing and adjusting
- 101 Testing and adjusting, Part 1
- Precautions before work
- Tools for testing, adjusting, and troubleshooting
- Sketches of special tools
- Measuring engine speed
- Measuring exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Measuring blow-by pressure
- Testing engine oil pressure
- Measuring intake air (boost) pressure
- Handling fuel system equipment
- Releasing residual pressure in fuel system
- Measuring fuel pressure
- Measuring fuel return rate and leakage
- Bleeding air from fuel circuit
- Checking leakage in fuel system
- Handling cylinder cut-out mode operation
- Handling no-injection cranking operation
- Handling controller voltage circuit
- Check of muffler and muffler stack for looseness and damage
- Check of muffler function
- Check of installed condition of cylinder head and manifolds
- Check of engine piping for damage and looseness
- Testing and adjusting air conditioner compressor belt tension
- Replacing alternator belt
- 102 Testing and adjusting, Part 2
- Checking operating force of accelerator pedal
- Checking directional lever
- Testing and adjusting HST oil pressure
- Testing clutch control pressure
- Testing and adjusting steering wheel
- Testing and adjusting steering oil pressure
- Bleeding air from steering circuit
- Testing hydraulic fan
- Measuring brake pedal
- Testing and adjusting brake pedal linkage
- Measuring brake performance
- Testing and adjusting accumulator charge pressure
- Testing wheel brake oil pressure
- Testing wear of brake disc
- Bleeding air from wheel brake circuit
- Releasing residual pressure in brake accumulator circuit
- Testing parking brake performance
- Testing and adjusting parking brake control cable
- Measuring and adjusting work equipment control lever
- Testing and adjusting work equipment hydraulic pressure
- Testing work equipment PPC oil pressure
- Bleeding air from hydraulic circuit
- Releasing remaining pressure in hydraulic circuit
- Testing and adjusting bucket positioner
- Testing and adjusting boom kick- out switch
- Checking proximity switch operation pilot lamp
- Procedure for testing diodes
- Preparation work for troubleshooting for electric system
- Starting KOMTRAX terminal operations
- Indicator lamps of KOMTRAX terminal
- Adjustment of rearview camera angle
- 103 Testing and adjusting, Part 3
- Adjusting machine monitor
- Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
- Special functions of machine monitor (EMMS)
- Pm clinic inspection chart
- 40 Troubleshooting
- 100 Failure code table and fuse locations
- Precautions before work
- Failure codes table
- Fuse locations
- 200 General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Checking water pump for water leakage
- Classification and procedures of troubleshooting
- Information contained in troubleshooting table
- Connection table for connector pin numbers
- T- branch box and T- branch adapter table
- 301 Troubleshooting by failure code (Display of code), Part 1
- Failure code [2G40ZG] Brake: Oil pressure reduction
- Failure code [6091NX] HST filter: Clogging
- Failure code [989FN1] Travel speed: Overrun alarm
- Failure code [AB00L6] Alternator R system: Hot short
- Failure code [AB00MA] Alternator R system: Ground fault/Disconnection /Low charge voltage
- Failure code [B@BAZG] Engine: Oil pressure reduction
- Failure code [B@BCNS] Engine: Overheat
- Failure code [B@BCZK] Engine: Low coolant level
- Failure code [B@C6NS] Front brake: High oil temperature
- Failure code [B@CRNS] HST: High oil temperature
- 302 Troubleshooting by failure code (Display of code), Part 2
- Failure code [CA111] Abnormality in engine controller
- Failure code [CA115] Engine Ne or Bkup speed sensor error
- Failure code [CA122] Charge pressure sensor high error
- Failure code [CA123] Charge pressure sensor low error
- Failure code [CA131] Throttle sensor high error
- Failure code [CA132] Throttle sensor low error
- Failure code [CA144] Coolant sensor high error
- Failure code [CA145] Coolant sensor low error
- Failure code [CA153] Charge temperature sensor high error
- Failure code [CA154] Charge temperature sensor low error
- Failure code [CA155] Derating of speed by abnormally high charge temperature
- Failure code [CA187] Sensor power supply 2 low error
- Failure code [CA221] Atmospheric pressure sensor high error
- Failure code [CA222] Atmospheric sensor low error
- Failure code [CA227] Sensor power supply 2 high error
- Failure code [CA234] Engine overspeed
- Failure code [CA238] Ne speed sensor power supply error
- Failure code [CA271] IMV (IMA) Short circuit
- Failure code [CA272] IMV (IMA) Disconnection
- Failure code [CA322] Injector #1 open/short error
- Failure code [CA324] Injector #3 open/short error
- Failure code [CA331] Injector #2 open/short error
- Failure code [CA332] Injector #4 open/short error
- Failure code [CA342] Calibration code inconsistency
- Failure code [CA351] Injectors drive circuit error
- Failure code [CA352] Sensor power supply 1 low error
- Failure code [CA386] Sensor power supply 1 high error
- 303 Troubleshooting by failure code (Display of code), Part 3
- Failure code [CA428] Abnormally high level in water sensor
- Failure code [CA429] Abnormally low level in water sensor
- Failure code [CA431] Idle validation switch error
- Failure code [CA432] Idle validation action error
- Failure code [CA435] Engine oil pressure switch error
- Failure code [CA441] Battery voltage low error
- Failure code [CA442] Battery voltage high error
- Failure code [CA449] Common rail pressure high error 2
- Failure code [CA451] Common rail pressure sensor high error
- Failure code [CA452] Common rail pressure sensor low error
- Failure code [CA488] Derating of torque by abnormally high charge temperature
- Failure code [CA553] Common rail pressure high error 1
- Failure code [CA559] Supply pump pressure very low error
- Failure code [CA689] Engine Ne speed sensor error
- Failure code [CA731] Engine Bkup speed sensor phase error
- Failure code [CA757] All continuous data lost error
- Failure code [CA778] Engine Bkup speed sensor error
- Failure code [CA1633] KOMNET datalink timeout error
- Failure code [CA2185] Throttle sensor supply voltage high error
- Failure code [CA2186] Throttle sensor power supply low error
- Failure code [CA2249] Supply pump pressure very low error 2
- Failure code [CA2311] Abnormality in IMV (IMA) solenoid
- Failure code [CA2555] Intake heater relay disconnection error
- Failure code [CA2556] Intake heater relay short circuit error
- 304 Troubleshooting by failure code (Display of code), Part 4
- Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short
- Failure code [D192KY] ECSS solenoid relay: Hot short
- Failure code [D1B0KA] HST safety relay: Disconnection
- Failure code [D1B0KB] HST safety relay: Ground fault
- Failure code [D1B0KY] HST safety relay: Hot short
- Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection
- Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection
- Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection
- Failure code [DAJ0KK] HST controller power supply: Low voltage
- Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality
- Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault
- Failure code [DAJ1L6] HST controller main power line: Hot short
- Failure code [DAJ2KK] Controller solenoid power supply: Low voltage
- Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness
- Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault
- Failure code [DAJ5KX] Sensor 5V power supply: Out of output range
- Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals
- Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection
- Failure code [DAJRMA] HST controller: Disagreement in option selection
- 305 Troubleshooting by failure code (Display of code), Part 5
- Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line
- Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality
- Failure code [DD1NLD] Fan reverse switch signal: Abnormality
- Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short
- Failure code [DDB6KB] Parking brake indicator signal: Ground fault
- Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble
- Failure code [DDB6L0] Parking brake reminder signal: Ground fault
- Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short
- Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault
- Failure code [DDD7KY] Travel speed control dial signal: Hot short
- Failure code [DDE5MA] Emergency steering operation switch: Disconnection
- Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
- Failure code [DDK6KY] FNR lever: Hot short
- Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)
- 306 Troubleshooting by failure code (Display of code), Part 6
- Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
- Failure code [DF10KB] Travel speed range selector switch: Hot short
- Failure code [DGH1KX] HST oil temperature sensor: Ground fault
- Failure code [DGR2KB] Brake oil temperature sensor: Ground fault
- Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short
- Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault
- Failure code [DHH1KY] HST oil pressure sensor: Hot short
- Failure code [DHTCL6] HST filter clogging sensor: Functional defect
- Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short
- Failure code [DLT3KX] Travel speed sensor B: Abnormality
- Failure code [DLT4KX] Travel speed sensor A: Abnormality
- Failure code [DLT4LC] Travel speed sensor A & B: Abnormality
- Failure code [DV00KY] Alarm buzzer: Hot short
- Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault
- Failure code [DW26KY] Motor 2 solenoid: Hot short
- Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short
- Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault
- 307 Troubleshooting by failure code (Display of code), Part 7
- Failure code [DX16KA] Fan EPC solenoid: Disconnection
- Failure code [DX16KB] Fan EPC solenoid: Ground fault
- Failure code [DX16KY] Fan EPC solenoid: Hot short
- Failure code [DX19KA] Motor 1 solenoid: Disconnection
- Failure code [DX19KB] Motor 1 solenoid: Ground fault
- Failure code [DX19KY] Motor 1 solenoid: Hot short
- Failure code [DX20KA] Clutch EPC solenoid: Disconnection
- Failure code [DX20KB] Clutch EPC solenoid: Ground fault
- Failure code [DX20KY] Clutch EPC solenoid: Hot short
- Failure code [DXH7KB] Reverse solenoid: Ground fault
- Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short
- Failure code [DXH8KB] Forward solenoid: Ground fault
- Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short
- Failure code [J141N1] Steering pump: Overrun alarm
- Failure code [M100N1] HST pump: Overrun alarm
- Failure code [M400N1] Motor 1: Overrun alarm
- 400 Troubleshooting of electrical system (E-mode)
- E-1 Engine does not start
- E-2 Preheater does not operate normally
- E-3 Travel speed is low or high
- E-4 ECSS does not operate
- E-5 ECSS keeps operating
- E-6 Defective boom kick-out function and cancellation
- E-7 Defective bucket positioner function and cancellation
- E-8 Defective lift arm FLOATING holding function and cancellation
- E-9 Travel direction selection system does not function
- E-10 Fan does not reverse
- E-11 Fan keeps rotating in reverse
- E-12 Wiper does not operate
- E-13 Windshield washer does not operate
- E-14 Headlamp, clearance lamp and tail lamp do not light up or go off
- E-15 Working lamp does not light up or go off
- E-16 Turn signal lamp and hazard lamp do not light up or go off
- E-17 Brake lamp does not light or it keeps lighting up
- E-18 Backup lamp does not light or it keeps lighting up
- E-19 Backup alarm does not sound or it keeps sounding
- E-20 Horn does not sound or it keeps sounding
- E-21 Alarm buzzer does not sound or it keeps sounding
- E-22 Air conditioner does not operate or stop
- E-23 The KOMTRAX system does not work properly
- E-24 Rearview monitor does not light up or backlight flickers
- E-25 Rearview monitor images are not displayed clearly
- E-26 Rearview monitor brightness cannot be adjusted
- E-27 Night lighting lamp of rearview monitor is abnormal
- E-28 Reverse interlock function of rearview monitor does not operate properly
- 500 Troubleshooting of hydraulic and mechanical system (H-mode)
- Method of using troubleshooting chart
- Failure code and cause table
- H-1 The machine does not start
- H-2 The travel speed is slow
- H-3 The traction force is weak
- H-4 Engine stalls when traveling or engine speed drops excessively
- H-5 Speed range is not shifted
- H-6 The steering wheel does not turn
- H-7 The steering wheel is heavy
- H-8 Steering wheel shakes or jerks
- H-9 Machine deviates naturally to one side when traveling
- H-10 The brake does not work or does not work well
- H-11 The brake is not released or is dragged
- H-12 The lift arm does not rise or lower
- H-13 The lift arm moves slowly or the lift arm rising force is insufficient
- H-14 When rising, the lift arm comes to move slowly at specific height
- H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)
- H-16 Hydraulic drifts of the lift arm occur often
- H-17 The lift arm wobbles during operation
- H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily
- H-19 The bucket does not tilt back
- H-20 The bucket moves slowly or the tilting-back force is insufficient
- H-21 The bucket comes to operate slowly in the midst of tilting-back
- H-22 The bucket cylinder cannot hold down the bucket
- H-23 Hydraulic drifts of the bucket occur often
- H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)
- H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily
- H-26 The control levers of the lift arm and bucket do not move smoothly and heavy
- H-27 The ECSS does not operate and machine pitches and bounces
- H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
- 600 Troubleshooting of engine (S-mode)
- Method of using troubleshooting charts
- S-1 Starting performance is poor
- S-2 Engine does not start
- S-3 Engine does not pick up smoothly
- S-4 Engine stops during operations
- S-5 Engine does not rotate smoothly
- S-6 Engine lacks output (or lacks power)
- S-7 Exhaust smoke is black (incomplete combustion)
- S-8 Oil consumption is excessive (or exhaust smoke is blue)
- S-9 Oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
- S-12 Oil pressure drops
- S-13 Oil level rises (Entry of coolant or fuel)
- S-14 Coolant temperature becomes too high (overheating)
- S-15 Abnormal noise is made
- S-16 Vibration is excessive
- 50 Disassembly and assembly
- 100 General information on disassembly and assembly
- Precautions before work
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- 200 Engine and cooling system
- Removal and installation of fuel supply pump assembly
- Removal and installation of fuel injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of engine hood assembly
- Removal and installation of radiator
- Removal and installation of air aftercooler
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of engine assembly
- 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
- 301 Power train, Part 1
- Disassembly and assembly of transfer assembly
- Removal and installation of parking brake assembly
- Disassembly and assembly of parking brake assembly
- 302 Power train, Part 2
- 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
- 400 Undercarriage and frame
- Removal and installation of center hinge pin
- Removal and installation of counterweight assembly
- 500 Hydraulic system
- Removal and installation of HST pump and 4-gear pump assembly
- Disassembly and assembly of HST pump assembly
- Removal and installation of HST motor 1 assembly
- Removal and installation of HST motor 2 assembly
- Disassembly and assembly of HST motor assembly
- Removal and installation of work equipment control valve assembly
- Removal and installation of hydraulic tank
- Disassembly and assembly of hydraulic cylinder assembly
- 600 Work equipment
- Removal and installation of work equipment assembly
- 700 Cab and its attachments
- Removal and installation of operator's cab and floor frame assembly
- Removal and installation of operator's cab glass (Stuck glass)
- Removal and installation of air conditioner unit
- 800 Electrical system
- Removal and installation of monitor panel
- Removal and installation of engine controller assembly
- Removal and installation of HST controller assembly
- Removal and installation of KOMTRAX terminal assembly
- 90 Diagrams and drawings
- 100 Hydraulic diagrams and drawings
- Hydraulic circuit diagram
- 200 Electrical diagrams and drawings
- Common electrical circuit diagram
- Specific electrical circuit diagram
- Connector list and stereogram
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