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Komatsu WA200-7 Shop Manual
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Komatsu WA200-7 Shop Manual

Komatsu WA200-7 Shop Manual

Wheel loader
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SEN06503-05
WHEEL LOADER
WA200
-7
80001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu WA200-7

  • Page 1 SEN06503-05 WHEEL LOADER WA200 80001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SJA03824-0000000000000 D655-3E0, GD655-3Y0 WHEEL LOADER WA200-7 Machine model Serial number WA200-7 80001 and up 00 Index and foreword WA200-7 00-1 Find manuals at https://best-manuals.com...
  • Page 4 Drive shaft ............................10-40 HST hydraulic piping diagram ......................10-41 HST pump ............................10-42 HST motor ............................10-50 Transfer ............................. 10-56 Clutch solenoid valve......................... 10-62 Axle..............................10-63 Differential ............................10-65 Torque proportioning differential......................10-68 00-2 WA200-7 Find manuals at https://best-manuals.com...
  • Page 5 Electrical system (HST controller system)..................10-186 System component parts......................... 10-202 HST controller ..........................10-208 ECSS............................... 10-212 KOMTRAX system .......................... 10-214 Engine starting circuit ........................10-217 Engine stopping circuit ........................10-219 Preheating system........................... 10-220 Automatic preheating system ......................10-221 WA200-7 00-3 Find manuals at https://best-manuals.com...
  • Page 6 Testing and adjusting steering circuit oil pressure................30-54 Bleeding air from steering circuit ..................... .30-56 Brake system ............................30-57 Testing brake pedal ......................... .30-57 Testing and adjusting brake pedal and linkage ................30-58 Testing braking performance......................30-59 00-4 WA200-7 Find manuals at https://best-manuals.com...
  • Page 7 Failure code [7RHYKB] Ground Fault of Fan Motor EPC Solenoid Output........40-123 Failure code [7RHYKY] Hot Short of Fan Motor EPC Solenoid Output .......... 40-125 Failure code [989FN1] Travel Speed Overrun Alarm ..............40-127 WA200-7 00-5 Find manuals at https://best-manuals.com...
  • Page 8 Failure code [CA556] Crankcase Press High Error 2 ..............40-213 Failure code [CA559] Rail Press Low Error 1.................. 40-214 Failure code [CA689] Engine Ne Speed Sensor Error ..............40-217 Failure code [CA691] Intake Air Temp Sens High Error..............40-219 00-6 WA200-7 Find manuals at https://best-manuals.com...
  • Page 9 Failure code [D1B0MC] Malfunction of HST Safety Relay .............. 40-310 Failure code [D1E6KA] Disconnection of Parking Brake Relay ............40-311 Failure code [D1E6KB] Ground Fault of Parking Brake Relay ............40-313 Failure code [D1E6KY] Hot Short of Parking Brake Relay.............. 40-315 WA200-7 00-7 Find manuals at https://best-manuals.com...
  • Page 10 Failure code [DK5EKY] Hot Short of 3rd Lever Potentiometer Sensor (Sub)........40-427 Failure code [DKA0KX] Failure of Boom Angle Sensor..............40-429 Failure code [DLM3KA] Failure of Cooling Fan Speed Sensor ............40-431 Failure code [DLM3LC] Ground Fault of Cooling Fan Speed Sensor ..........40-433 00-8 WA200-7 Find manuals at https://best-manuals.com...
  • Page 11 E-12 Directional selection does not work normally................40-540 E-13 Fan does not rotate in reverse....................40-551 E-14 Fan remains in reverse rotation mode ..................40-554 E-15 Wipers do not operate ......................40-556 E-16 Window washer does not operate ..................40-561 WA200-7 00-9...
  • Page 12 H-36 Fan speed is abnormal (too high or low, or fan does not rotate) ..........40-654 H-37 Unusual noise is heard from around fan................. 40-656 Troubleshooting of engine (S-mode)....................40-657 Information mentioned in troubleshooting table (S mode)............... 40-657 S-1 Engine does not crank when starting switch is turned to START position........ 40-658 00-10 WA200-7...
  • Page 13 Disassembly and assembly of parking brake assembly..............50-113 Removal and installation of front axle assembly ................50-119 Removal and installation of rear axle assembly ................50-121 Disassembly and assembly of axle housing assembly ..............50-124 Disassembly and assembly of differential assembly ............... 50-133 WA200-7 00-11...
  • Page 14 Charge valve ........................... 60-34 Slack adjuster ..........................60-36 Brake ............................... 60-37 Parking brake ..........................60-39 Undercarriage and frame ........................60-40 Axle mount and center hinge pin ..................... 60-40 Hydraulic system..........................60-44 Hydraulic tank..........................60-44 Work equipment control valve ......................60-45 00-12 WA200-7...
  • Page 15 Hydraulic diagrams and drawings......................90-3 Symbols used in hydraulic circuit diagrams ..................90-3 Hydraulic circuit diagram ........................90-5 Electrical diagrams and drawings ......................90-7 Symbols used in electric circuit diagrams ................... 90-7 Electrical circuit diagram ........................ 90-11 Index ................................WA200-7 00-13...
  • Page 16 Appropriate servicing and repair are extremely important to ensure safe operation of the machine. Theshop manual describes the effective and safe servicing and repair methods recommended by Komat- Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. The symbol mark is used for such matters that require special cautions during the work.
  • Page 17 When removing the part which is under internal pressure or reaction force of the spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately and release the pressure, then, remove the part. WA200-7 00-15...
  • Page 18 4. Do not lift up the load at an angle. When lowering a load, pay attention to the fol- lowing. 1. When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. 00-16 WA200-7...
  • Page 19 After finishing the work, stop the hoist at the one wrench to fix and use the other one to loos- specified position and raise the hook to at least en the nut. 2 meters above the floor. Do not leave the sling attached to the hook. WA200-7 00-17...
  • Page 20 Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). a Example of fitting of O-ring An O-ring is fitted to every joint of the air con- ditioner piping. 00-18 WA200-7...
  • Page 21 Fire around the machine due to highly heated exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust gas discharged during purifica- tion process (regeneration) can be at higher temperature than that from existing models.
  • Page 22 As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations. 00-20 WA200-7...
  • Page 23 (Rev. 2012/10) Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. Materials and specifications are subject to change without notice.
  • Page 24 Places where oil, coolant, etc. must be drained and the quantity to be drained are Drain indicated. Unit In this shop manual, the units are indicated with International System of units (SI). For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }. 00-22 WA200-7...
  • Page 25 When some parts are repaired, the clearance is generally adjusted to the standard clearance. WA200-7 00-23...
  • Page 26 "allowable interfer- ence". The allowable interference shows the repair limit of the part of smaller tolerance. The parts whose interferences are out of the al- lowable interference must be replaced or re- paired. 00-24 WA200-7...
  • Page 27 If any dirt or dust sticks the parts of the fuel sys- tem, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. The common rail fuel injection system (CRI) con- sists of more precise parts than the parts used in the conventional fuel injection pump and nozzle.
  • Page 28 00 Index and foreword Handling of intake system parts Handling of intake system parts (Rev.2013/10) The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mecha- nism) than the parts used in the conventional tur- bocharger. If foreign material enters this system, it may cause a failure.
  • Page 29 If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil. WA200-7 00-27...
  • Page 30 The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device. 00-28 WA200-7...
  • Page 31 3. Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) ber cap will move approximately 3.5mm to- a Since some hydraulic oil flows out, prepare ward the hose, however, it is not a problem. an oil container. WA200-7 00-29...
  • Page 32 (Fig. 9) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8) 00-30 WA200-7...
  • Page 33 (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12) WA200-7 00-31...
  • Page 34 The corroded or oxidized contact sur- faces may become shiny again (and contact may become normal) by connecting and discon- necting the connectors approximately 10 times. 00-32 WA200-7...
  • Page 35 Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air. WA200-7 00-33...
  • Page 36 For connectors fitted with the boot, correct any extrusion of the boot. In addition, if the wiring harness or the clamp is out of the po- sition, put it in its original position. 00-34 WA200-7...
  • Page 37 Connection too hot, as it causes deformation or damage 1. Push in female connector (2) horizontally until to the connector. the lock clicks. (Arrow: x) WA200-7 00-35...
  • Page 38 (1) cannot be pulled out toward you unless part A floats, float part A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) to- ward you. a Lock (L2) is located in the back of connector (1). 00-36 WA200-7...
  • Page 39 1. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 series Connection 1. Insert the connector securely until a click is heard. (AMP-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. WA200-7 00-37...
  • Page 40 Pull the connector straight up. Connection 1. Insert the connector to the end while aligning its grove to the other. 2. Turn housing (H1) in the direction of the arrow until it "clicks". 00-38 WA200-7...
  • Page 41 Do not place the controller on oil, water, or soil, or in a place that can be heated to a high temperature even for a short period of time. (Place it on a suitable dry stand.) WA200-7 00-39...
  • Page 42 CAVS excavators for automobile (nominal No. 1.25 and lower) (Type 2) General wiring for extremely Heatresistant Heat-resistant cross lowvoltage wire -50 to +110 cold weather specification Wiring at linked polyethylene for automobile temperature place high ambient 00-40 WA200-7...
  • Page 43 11/round 16/round — — — strands/Diam compression compression compression eter of strand Crosssec- Conductor tional area — 0.56 — 0.88 — 1.29 d (approx.) — — — Cover Standard — — — "f" of nominal No. denotes "flexible". WA200-7 00-41...
  • Page 44 — — Others — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — — 00-42 WA200-7...
  • Page 45 Disconnection of face seal type hoses and tubes Hose side Pipe joint side Nominal No. O-ring (3) Plug (1) Nut (2) 07376 - 70210 02789-00210 02896-11008 07376 - 70315 02789-00315 02896-11009 07376 - 70422 02789-00422 02896-11012 07376 - 70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 WA200-7 00-43...
  • Page 46 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032 01044 51035 07379- 07372- 58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032 01250 51035 07379- 01010- 66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232 01260 81245 07379- 07372- 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232 01460 51240 00-44 WA200-7...
  • Page 47 Removal of pipe joints of O-ring boss type Nominal No. Plug (1) O-ring (2) 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 WA200-7 00-45...
  • Page 48 If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is pushed out, and that can cause oil leakage. 00-46 WA200-7...
  • Page 49 When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the cool- ant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 50 3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For Key Person)". 00-48 WA200-7...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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80001