Download Komatsu WA200-7 Wheel Loader Service Manual SN 80001 & Up 

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This service manual contains detailed maintenance, service, repair and troubleshooting procedures for the WA200-7 Wheel Loader (SN 80001 & Up). The service manual is a must for all WA200-7 Wheel Loader (SN 80001 & Up) owners, operators and mechanics. Print off the pages including detailed diagrams and accurate illustrations you need at any time and save time and money on repair.

WA200-7 Wheel Loader (SN 80001 & Up) Service Manual Topic List:

Specifications
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
VFT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDOC muffler
Damper
Cooling system
Cooling system hydraulic piping diagram
Cooling fan motor
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
Steering system
Steering piping diagram
Orbitrol valve
Steering column
Priority valve
Emergency steering valve
Brake system
Brake piping diagram
Brake valve
Charge valve
Accumulator (for brake)
Slack adjuster
Brake
Parking brake control
Parking brake
Parking brake cylinder
Parking brake solenoid valve
Inching valve
Undercarriage and frame
Axle mount and center hinge pin
Hydraulic system
Hydraulic component layout
Work equipment control lever linkage
Hydraulic tank
Accumulator (for PPC circuit)
Work equipment control valve
PPC valve
Attachment EPC valve
Work equipment lock solenoid valve
ECSS valve
Accumulator (for ECSS)
2-way restrictor valve
Cushion valve
Accumulator (for oil cooler circuit)
Quadruple gear pump
Quick coupler solenoid valve
Work equipment
Work equipment linkage
Bucket
Bucket positioner and boom kick-out
Cab and its attachments
Cab
Electrical system
Machine monitor system
Machine monitor
Electrical system (HST controller system)
System component parts
HST controller
ECSS
KOMTRAX system
Engine starting circuit
Engine stopping circuit
Preheating system
Automatic preheating system
Manual preheating system
Engine output limit function
Automatic warm-up function
Parking brake control system
Multi-function mono-lever
Sensor

Standard value table
Standard value table
Standard value table for engine
Standard value table for machine

Testing and adjusting
Related information on testing and adjusting
Tools for testing and adjusting
Engine and cooling system
Testing and adjusting engine speed
Testing exhaust gas temperature
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing boost pressure
Handling equipment of fuel system devices
Releasing remaining pressure from fuel system
Testing fuel pressure
Testing fuel discharge, return and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing KDPF and muffler stack for looseness and damage
Testing KDOC function
Testing installed condition of cylinder heads and manifolds
Testing engine piping for damage and looseness
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Power train
Testing oil leakage from axle final drive
Testing drive shaft for looseness, backlash, and damage
Testing accelerator pedal
Testing and adjusting HST oil pressure
Testing transfer clutch control pressure
Steering system
Testing directional lever
Testing and adjusting steering wheel
Testing work equipment control lever
Testing and adjusting steering circuit oil pressure
Bleeding air from steering circuit
Brake system
Testing brake pedal
Testing and adjusting brake pedal and linkage
Testing braking performance
Testing and adjusting accumulator charge pressure
Testing wheel brake oil pressure
Testing lowering of wheel brake pressure
Testing wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing remaining pressure in brake accumulator circuit
Testing parking brake performance
Testing parking brake release pressure
Method of releasing parking brake manually
Hydraulic system
Testing and adjusting cooling fan speed
Testing cooling fan pump circuit oil pressure
Testing work equipment PPC oil pressure
Testing and adjusting work equipment oil pressure
Bleeding air from each part
Releasing remaining pressure in hydraulic circuit
Work equipment
Testing and adjusting bucket positioner
Testing and adjusting boom kick-out switch
Checking the proximity switch working pilot lamp
Electrical system
Adjusting replaced, reassembled or added sensor, controller, etc
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Lamp indication of KOMTRAX terminal
Handling voltage circuit of controller
Test diodes
Pm Clinic
Pm Clinic service

Troubleshooting
Related information on troubleshooting
Points to remember when performing troubleshooting
How to proceed in troubleshooting
Checks before troubleshooting
Check procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures of troubleshooting
Symptom and troubleshooting No
Information described in troubleshooting table
Procedure for troubleshooting of open circuit in wiring harness of pressure sensor system
Connector list and layout
Connection table of connector by No
T-box and T-adapter list
Fuse location table
Failure code list
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting for hydraulic and mechanical system (H-mode)
Information mentioned in troubleshooting table (S mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine hood assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of air aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of engine assembly
Removal and installation of belt for alternator and air conditioner compressor
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
Removal and installation of KCCV ventilator assembly
Removal and installation of KDOC muffler
Removal and installation of EGR cooler assembly
Removal and installation of EGR valve assembly
Power train
Removal and installation of transfer assembly
Disassembly and assembly of transfer assembly
Removal and installation of parking brake assembly
Removal and installation of parking brake cylinder assembly
Disassembly and assembly of parking brake assembly
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
Undercarriage and frame
Removal and installation of center hinge pin
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of HST pump and quadruple type gear pump assembly
Removal and installation of HST motor 1 assembly
Removal and installation of HST motor 2 assembly
Removal and installation of work equipment control valve assembly
Removal and installation of ECSS (Electronically Controlled Suspension System) valve assembly

Removal and installation of hydraulic tank assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator’s cab and floor frame assembly
Removal and installation of operator’s cab glass (adhered glass)
Disassembly and assembly of operator’s seat
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
Electrical system
Removal and installation of machine monitor
Removal and installation of engine controller assembly
Removal and installation of HST controller assembly
Removal and installation of KOMTRAX terminal assembly
60 Maintenance standard
Engine and cooling system
Engine mount and transfer mount
Damper
Cooling system
Cooling fan motor
Power train
Drive shaft
Transfer
Axle
Differential
Limited slip differential
Final drive
Steering system
Orbitrol valve
Steering cylinder
Steering column
Priority valve
Emergency steering valve
Brake system
Charge valve
Slack adjuster
Brake
Parking brake
Undercarriage and frame
Axle mount and center hinge pin
Hydraulic system
Hydraulic tank
Work equipment control valve
PPC valve
ECSS valve
Quadruple gear pump
Work equipment
00 Index and foreword
Index
Work equipment linkage
Bucket
Bucket positioner and boom kick-out
Work equipment cylinder
80 Appendix
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Functions of main components in air conditioner unit
Blower and intake unit
Compressor
Condenser
Receiver drier
Air conditioner control panel
Procedure for troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Details of air conditioner unit
Parts and connectors layout
Inspection by self-diagnosis function (displays diagnosis on the control panel)
Testing temperature control system
Testing FRESH/RECIRC air changeover
Testing evaporator temperature sensor
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information described in troubleshooting table
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for FRESH/RECIRC air changeover
Connection of service tool
Troubleshooting by gauge pressure
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
Handling of compressor oil
90 Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Electrical circuit diagram
Index

Covers: Komatsu WA200-7 Wheel Loader (Serial No. 80001 and up)
Pages: 1,556
Format: PDF
Compatibility: Windows/Mac/Tablet
File size: 121mb
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