wa1200-6 shop manual
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WHEEL LOADER
SEN05475-01
WA1200-6SERIAL NUMBERS 60001 and up
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WA1200-6 1(01)
Notice of revision
Notice of revision1th. revisionThe affected pages are indicated by the use of thefollowing marks. It is requested that necessary ac-tions must be taken to these pages according to thelist below.
2011/10
List of revised pages
Mark Indication Action required
Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Revision number Mark PageRevision number Mark Page
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Revision number
Q 1 (01) 00-42 10-15 10-56Q 2 (01) 00-43 10-16 10-57Q 3 (01) 00-44 10-17 10-58Q 4 (01) 00-45 10-18 10-59Q 5 (01) 00-46 10-19 10-60Q 6 (01) 00-47 10-20 10-61Q 7 (01) 00-48 10-21 10-62Q 8 (01) 00-49 10-22 10-63Q 9 (01) 00-50 10-23 10-64Q 10 (01) 00-51 10-24 10-65Q 11 (01) 00-52 10-25 10-66Q 12 (01) 00-53 10-26 10-67
00-1 00-54 10-27 10-6800-2 00-55 10-28 10-6900-3 00-56 10-29 10-7000-4 00-57 10-30 10-7100-5 00-58 10-31 10-7200-6 01-1 10-32 10-7300-7 01-2 10-33 10-7400-8 01-3 10-34 10-7500-9 01-4 10-35 10-7600-10 01-5 10-36 10-7700-11 01-6 10-37 10-7800-12 01-7 10-38 10-7900-13 01-8 10-39 10-8000-26 01-9 10-40 10-8100-27 01-10 10-41 10-8200-28 10-1 10-42 10-8300-29 10-2 10-43 10-8400-30 10-3 10-44 10-8500-31 10-4 10-45 10-8600-32 10-5 10-46 10-8700-33 10-6 10-47 10-8800-34 10-7 10-48 10-8900-35 10-8 10-49 10-9000-36 10-9 10-50 10-9100-37 10-10 10-51 10-9200-38 10-11 10-52 10-9300-39 10-12 10-53 10-9400-40 10-13 10-54 10-9500-41 10-14 10-55 10-96
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Notice of revision
2 WA1200-6(01)
10-97 10-149 10-201 10-25310-98 10-150 10-202 10-25410-99 10-151 10-203 10-255
10-100 10-152 10-204 10-25610-101 10-153 10-205 10-25710-102 10-154 10-206 10-25810-103 10-155 10-207 10-25910-104 10-156 10-208 10-26010-105 10-157 10-209 10-26110-106 10-158 10-210 10-26210-107 10-159 10-211 10-26310-108 10-160 10-212 10-26410-109 10-161 10-213 10-26510-110 10-162 10-214 10-26610-111 10-163 10-215 10-26710-112 10-164 10-216 10-26810-113 10-165 10-217 10-26910-114 10-166 10-218 10-27010-115 10-167 10-219 10-27110-116 10-168 10-220 10-27210-117 10-169 10-221 10-27310-118 10-170 10-222 10-27410-119 10-171 10-223 10-27510-120 10-172 10-224 10-27610-121 10-173 10-225 10-27710-122 10-174 10-226 10-27810-123 10-175 10-227 10-27910-124 10-176 10-228 10-28010-125 10-177 10-229 10-28110-126 10-178 10-230 10-28210-127 10-179 10-231 10-28310-128 10-180 10-232 10-28410-129 10-181 10-233 10-28510-130 10-182 10-234 10-28610-131 10-183 10-235 10-28710-132 10-184 10-236 10-28810-133 10-185 10-237 10-28910-134 10-186 10-238 10-29010-135 10-187 10-239 10-29110-136 10-188 10-240 10-29210-137 10-189 10-241 10-29310-138 10-190 10-242 10-29410-139 10-191 10-243 10-29510-140 10-192 10-244 10-29610-141 10-193 10-245 10-29710-142 10-194 10-246 10-29810-143 10-195 10-247 10-29910-144 10-196 10-248 10-30010-145 10-197 10-249 10-30110-146 10-198 10-250 10-30210-147 10-199 10-251 10-30310-148 10-200 10-252 10-304
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WA1200-6 3(01)
Notice of revision
10-305 10-357 30-23 30-7510-306 10-358 30-24 30-7610-307 10-359 30-25 30-7710-308 10-360 30-26 30-7810-309 10-361 30-27 30-7910-310 10-362 30-28 30-8010-311 10-363 30-29 30-8110-312 10-364 30-30 30-8210-313 10-365 30-31 30-8310-314 10-366 30-32 30-8410-315 10-367 30-33 30-8510-316 10-368 30-34 30-8610-317 10-369 30-35 30-8710-318 10-370 30-36 30-8810-319 10-371 30-37 30-8910-320 10-372 30-38 30-9010-321 10-373 30-39 30-9110-322 10-374 30-40 30-9210-323 10-375 30-41 30-9310-324 10-376 30-42 30-9410-325 10-377 30-43 30-9510-326 10-378 30-44 30-9610-327 20-1 30-45 30-9710-328 20-2 30-46 30-9810-329 20-3 30-47 30-9910-330 20-4 30-48 30-10010-331 20-5 30-49 30-10110-332 20-6 30-50 30-10210-333 20-7 30-51 30-10310-334 20-8 30-52 30-10410-335 30-1 30-53 30-10510-336 30-2 30-54 30-10610-337 30-3 30-55 30-10710-338 30-4 30-56 30-10810-339 30-5 30-57 30-10910-340 30-6 30-58 30-11010-341 30-7 30-59 30-11110-342 30-8 30-60 30-11210-343 30-9 30-61 30-11310-344 30-10 30-62 30-11410-345 30-11 30-63 30-11510-346 30-12 30-64 30-11610-347 30-13 30-65 30-11710-348 30-14 30-66 30-11810-349 30-15 30-67 30-11910-350 30-16 30-68 30-12010-351 30-17 30-69 30-12110-352 30-18 30-70 30-12210-353 30-19 30-71 30-12310-354 30-20 30-72 30-12410-355 30-21 30-73 30-12510-356 30-22 30-74 30-126
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Notice of revision
4 WA1200-6(01)
30-127 30-179 30-231 40-4130-128 30-180 30-232 40-4230-129 30-181 30-233 40-4330-130 30-182 30-234 40-4430-131 30-183 30-235 40-4530-132 30-184 30-236 40-4630-133 30-185 30-237 40-4730-134 30-186 30-238 40-4830-135 30-187 30-239 40-4930-136 30-188 30-240 40-5030-137 30-189 30-241 40-5130-138 30-190 30-242 40-5230-139 30-191 40-1 40-5330-140 30-192 40-2 40-5430-141 30-193 40-3 40-5530-142 30-194 40-4 40-5630-143 30-195 40-5 40-5730-144 30-196 40-6 40-5830-145 30-197 40-7 40-5930-146 30-198 40-8 40-6030-147 30-199 40-9 40-6130-148 30-200 40-10 40-6230-149 30-201 40-11 40-6330-150 30-202 40-12 40-6430-151 30-203 40-13 40-6530-152 30-204 40-14 40-6630-153 30-205 40-15 40-6730-154 30-206 40-16 40-6830-155 30-207 40-17 40-6930-156 30-208 40-18 40-7030-157 30-209 40-19 40-7230-158 30-210 40-20 40-7330-159 30-211 40-21 40-7430-160 30-212 40-22 40-7530-161 30-213 40-23 40-7630-162 30-214 40-24 40-7730-163 30-215 40-25 40-7830-164 30-216 40-26 40-7930-165 30-217 40-27 40-8030-166 30-218 40-28 40-8130-167 30-219 40-29 40-8230-168 30-220 40-30 40-8330-169 30-221 40-31 40-8430-170 30-222 40-32 40-8530-171 30-223 40-33 40-8630-172 30-224 40-34 40-8730-173 30-225 40-35 40-8830-174 30-226 40-36 40-8930-175 30-227 40-37 40-9030-176 30-228 40-38 40-9130-177 30-229 40-39 40-9230-178 30-230 40-40 40-93
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WA1200-6 5(01)
Notice of revision
40-94 40-140 40-192 40-24440-95 40-141 40-193 40-24540-96 40-142 40-194 40-24640-97 40-143 40-195 40-24740-98 40-144 40-196 40-24840-99 40-145 40-197 40-249
40-100 40-146 40-198 40-25040-101 40-147 40-199 40-25140-102 40-148 40-200 40-25240-103 40-149 40-201 40-25340-104 40-150 40-202 40-25440-105 40-151 40-203 40-25540-106 40-152 40-204 40-25640-107 40-153 40-205 40-25740-108 40-154 40-206 40-258
q 40-109 (01) 40-155 40-207 40-259Q 40-109-1 (01) 40-156 40-208 40-260Q 40-109-2 (01) 40-157 40-209 40-261Q 40-109-3 (01) 40-158 40-210 40-262Q 40-109-4 (01) 40-159 40-211 40-263Q 40-109-5 (01) 40-160 40-212 40-264Q 40-109-6 (01) 40-161 40-213 40-265
40-110 40-162 40-214 40-26640-111 40-163 40-215 40-26740-112 40-164 40-216 40-26840-113 40-165 40-217 40-26940-114 40-166 40-218 40-27040-115 40-167 40-219 40-27140-116 40-168 40-220 40-27240-117 40-169 40-221 40-27340-118 40-170 40-222 40-27440-119 40-171 40-223 40-27540-120 40-172 40-224 40-27640-121 40-173 40-225 40-27740-122 40-174 40-226 40-27840-123 40-175 40-227 40-27940-124 40-176 40-228 40-28040-125 40-177 40-229 40-28140-126 40-178 40-230 40-28240-127 40-179 40-231 40-28340-128 40-180 40-232 40-28440-129 40-181 40-233 40-28540-130 40-182 40-234 40-28640-131 40-183 40-235 40-28740-132 40-184 40-236 40-28840-133 40-185 40-237 40-28940-134 40-186 40-238 40-29040-135 40-187 40-239 40-29140-136 40-188 40-240 40-29240-137 40-189 40-241 40-29340-138 40-190 40-242 40-29440-139 40-191 40-243 40-295
Mark Page Revision number Mark PageRevision number Mark Page
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Notice of revision
6 WA1200-6(01)
40-296 40-348 40-400 40-45240-297 40-349 40-401 40-45340-298 40-350 40-402 40-45440-299 40-351 40-403 40-45540-300 40-352 40-404 40-45640-301 40-353 40-405 40-45740-302 40-354 40-406 40-45840-303 40-355 40-407 40-45940-304 40-356 40-408 40-46040-305 40-357 40-409 40-46140-306 40-358 40-410 40-46240-307 40-359 40-411 40-46340-308 40-360 40-412 40-46440-309 40-361 40-413 40-46540-310 40-362 40-414 40-46640-311 40-363 40-415 40-46740-312 40-364 40-416 40-46840-313 40-365 40-417 40-46940-314 40-366 40-418 40-47040-315 40-367 40-419 40-47140-316 40-368 40-420 40-47240-317 40-369 40-421 40-47340-318 40-370 40-422 40-47440-319 40-371 40-423 40-47540-320 40-372 40-424 40-47640-321 40-373 40-425 40-47740-322 40-374 40-426 40-47840-323 40-375 40-427 40-47940-324 40-376 40-428 40-48040-325 40-377 40-429 40-48140-326 40-378 40-430 40-48240-327 40-379 40-431 40-48340-328 40-380 40-432 40-48440-329 40-381 40-433 40-48540-330 40-382 40-434 40-48640-331 40-383 40-435 40-48740-332 40-384 40-436 40-48840-333 40-385 40-437 40-48940-334 40-386 40-438 40-49040-335 40-387 40-439 40-49140-336 40-388 40-440 40-49240-337 40-389 40-441 40-49340-338 40-390 40-442 40-49440-339 40-391 40-443 40-49540-340 40-392 40-444 40-49640-341 40-393 40-445 40-49740-342 40-394 40-446 40-49840-343 40-395 40-447 40-49940-344 40-396 40-448 40-50040-345 40-397 40-449 40-50140-346 40-398 40-450 40-50240-347 40-399 40-451 40-503
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WA1200-6 7(01)
Notice of revision
40-504 40-556 40-608 40-66040-505 40-557 40-609 40-66140-506 40-558 40-610 40-66240-507 40-559 40-611 40-66340-508 40-560 40-612 40-66440-509 40-561 40-613 40-66540-510 40-562 40-614 40-66640-511 40-563 40-615 40-66740-512 40-564 40-616 40-66840-513 40-565 40-617 40-66940-514 40-566 40-618 40-67040-515 40-567 40-619 40-67140-516 40-568 40-620 40-67240-517 40-569 40-621 40-67340-518 40-570 40-622 40-67440-519 40-571 40-623 40-67540-520 40-572 40-624 40-67640-521 40-573 40-625 40-67740-522 40-574 40-626 40-67840-523 40-575 40-627 40-67940-524 40-576 40-628 40-68040-525 40-577 40-629 40-68140-526 40-578 40-630 40-68240-527 40-579 40-631 40-68340-528 40-580 40-632 40-68440-529 40-581 40-633 40-68540-530 40-582 40-634 40-68640-531 40-583 40-635 40-68740-532 40-584 40-636 40-68840-533 40-585 40-637 40-68940-534 40-586 40-638 40-69040-535 40-587 40-639 40-69140-536 40-588 40-640 40-69240-537 40-589 40-641 40-69340-538 40-590 40-642 40-69440-539 40-591 40-643 40-69540-540 40-592 40-644 40-69640-541 40-593 40-645 40-69740-542 40-594 40-646 40-69840-543 40-595 40-647 40-69940-544 40-596 40-648 40-70040-545 40-597 40-649 40-70140-546 40-598 40-650 40-70240-547 40-599 40-651 40-70340-548 40-600 40-652 40-70440-549 40-601 40-653 40-70540-550 40-602 40-654 40-70640-551 40-603 40-655 40-70740-552 40-604 40-656 40-70840-553 40-605 40-657 40-70940-554 40-606 40-658 40-71040-555 40-607 40-659 40-711
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Notice of revision
8 WA1200-6(01)
40-712 50-44 50-96 50-14840-713 50-45 50-97 50-14940-714 50-46 50-98 50-15040-715 50-47 50-99 50-15140-716 50-48 50-100 50-15240-717 50-49 50-101 50-15340-718 50-50 50-102 50-15440-719 50-51 50-103 50-15540-720 50-52 50-104 50-15650-1 50-53 50-105 50-15750-2 50-54 50-106 50-15850-3 50-55 50-107 50-15950-4 50-56 50-108 50-16050-5 50-57 50-109 50-16150-6 50-58 50-110 50-16250-7 50-59 50-111 50-16350-8 50-60 50-112 50-16450-9 50-61 50-113 50-16550-10 50-62 50-114 50-16650-11 50-63 50-115 50-16750-12 50-64 50-116 50-16850-13 50-65 50-117 50-16950-14 50-66 50-118 50-17050-15 50-67 50-119 50-17150-16 50-68 50-120 50-17250-17 50-69 50-121 50-17350-18 50-70 50-122 50-17450-19 50-71 50-123 50-17550-20 50-72 50-124 50-17650-21 50-73 50-125 50-17750-22 50-74 50-126 50-17850-23 50-75 50-127 50-17950-24 50-76 50-128 50-18050-25 50-77 50-129 50-18150-26 50-78 50-130 50-18250-27 50-79 50-131 50-18350-28 50-80 50-132 50-18450-29 50-81 50-133 50-18550-30 50-82 50-134 50-18650-31 50-83 50-135 50-18750-32 50-84 50-136 50-18850-33 50-85 50-137 50-18950-34 50-86 50-138 50-19050-35 50-87 50-139 50-19150-36 50-88 50-140 50-19250-37 50-89 50-141 50-19350-38 50-90 50-142 50-19450-39 50-91 50-143 50-19550-40 50-92 50-144 50-19650-41 50-93 50-145 50-19750-42 50-94 50-146 50-19850-43 50-95 50-147 50-199
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WA1200-6 9(01)
Notice of revision
50-200 50-252 50-304 50-35650-201 50-253 50-305 50-35750-202 50-254 50-306 50-35850-203 50-255 50-307 50-35950-204 50-256 50-308 50-36050-205 50-257 50-309 50-36150-206 50-258 50-310 50-36250-207 50-259 50-311 50-36350-208 50-260 50-312 50-36450-209 50-261 50-313 50-36550-210 50-262 50-314 50-36650-211 50-263 50-315 50-36750-212 50-264 50-316 50-36850-213 50-265 50-317 50-36950-214 50-266 50-318 50-37050-215 50-267 50-319 50-37150-216 50-268 50-320 50-37250-217 50-269 50-321 50-37350-218 50-270 50-322 50-37450-219 50-271 50-323 50-37550-220 50-272 50-324 50-37650-221 50-273 50-325 50-37750-222 50-274 50-326 50-37850-223 50-275 50-327 50-37950-224 50-276 50-328 50-38050-225 50-277 50-329 50-38150-226 50-278 50-330 50-38250-227 50-279 50-331 50-38350-228 50-280 50-332 50-38450-229 50-281 50-333 50-38550-230 50-282 50-334 50-38650-231 50-283 50-335 50-38750-232 50-284 50-336 50-38850-233 50-285 50-337 50-38950-234 50-286 50-338 50-39050-235 50-287 50-339 50-39150-236 50-288 50-340 50-39250-237 50-289 50-341 50-39350-238 50-290 50-342 50-39450-239 50-291 50-343 50-39550-240 50-292 50-344 50-39650-241 50-293 50-345 50-39750-242 50-294 50-346 50-39850-243 50-295 50-347 50-39950-244 50-296 50-348 50-40050-245 50-297 50-349 50-40150-246 50-298 50-350 50-40250-247 50-299 50-351 50-40350-248 50-300 50-352 50-40450-249 50-301 50-353 50-40550-250 50-302 50-354 50-40650-251 50-303 50-355 50-407
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Notice of revision
10 WA1200-6(01)
50-408 60-16 60-68 80-4250-409 60-17 60-69 80-4350-410 60-18 60-70 80-4450-411 60-19 60-71 80-4550-412 60-20 60-72 80-4650-413 60-21 60-73 80-4750-414 60-22 60-74 80-4850-415 60-23 60-75 80-4950-416 60-24 60-76 80-5050-417 60-25 60-77 80-5150-418 60-26 60-78 80-5250-419 60-27 80-1 80-5350-420 60-28 80-2 80-5450-421 60-29 80-3 80-5550-422 60-30 80-4 80-5650-423 60-31 80-5 80-5750-424 60-32 80-6 80-5850-425 60-33 80-7 90-150-426 60-34 80-8 90-250-427 60-35 80-9 90-350-428 60-36 80-10 90-450-429 60-37 80-11 90-550-430 60-38 80-12 90-650-431 60-39 80-13 90-750-432 60-40 80-14 90-850-433 60-41 80-15 90-950-434 60-42 80-16 90-1050-435 60-43 80-17 90-1150-436 60-44 80-18 90-1250-437 60-45 80-19 90-1350-438 60-46 80-20 90-1450-439 60-47 80-21 90-1550-440 60-48 80-22 90-1650-441 60-49 80-23 90-1750-442 60-50 80-24 90-1850-443 60-51 80-25 90-1950-444 60-52 80-26 90-2060-1 60-53 80-27 90-2160-2 60-54 80-28 90-2260-3 60-55 80-29 90-2360-4 60-56 80-30 90-2460-5 60-57 80-31 90-2560-6 60-58 80-32 90-2660-7 60-59 80-33 90-2760-8 60-60 80-34 90-2860-9 60-61 80-35 90-2960-10 60-62 80-36 90-3060-11 60-63 80-37 90-3160-12 60-64 80-38 90-3260-13 60-65 80-39 90-3360-14 60-66 80-40 90-3460-15 60-67 80-41 90-35
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WA1200-6 11(01)
Notice of revision
90-3690-3790-3890-3990-4090-4190-4290-4390-44
12345678
q Colophon (01)
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Notice of revision
12 WA1200-6(01)
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WA1200-6
SEN0537702-00 00-1
WA1200-6
Shop Manual 00- 1WHEEL LOADERWA1200-6
Machine model Serial numberWA1200-6 60001 and up
00 Index and foreword 00-1
00-1
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Table of Contents
WA1200-6
Table of Contents 00-2
00 Index and forewordTable of contents .................................................................................................................... 00 - 2
Table of contents ................................................................................................................. 00 - 2Foreword and general information .......................................................................................... 00- 16
Safety notice ........................................................................................................................ 00- 16How to read the shop manual .............................................................................................. 00- 21Explanation of terms for maintenance standard .................................................................. 00- 23Handling of hydraulic components....................................................................................... 00- 25Method of disconnecting and connecting push-pull type coupler ........................................ 00- 27Handling of electric equipment............................................................................................. 00- 30How to read electric wire code............................................................................................. 00- 40Precautions when performing work...................................................................................... 00- 43Standard tightening torque table.......................................................................................... 00- 46List of abbreviation............................................................................................................... 00- 50Conversion table .................................................................................................................. 00- 54
01 SpecificationSpecification............................................................................................................................ 01- 3
Specification dimension drawing.......................................................................................... 01- 3Specifications....................................................................................................................... 01- 4Weight table ......................................................................................................................... 01- 7Table of fuel, coolant and lubricants .................................................................................... 01- 9
10 Structure and functionEngine and cooling system ..................................................................................................... 10- 4
Damper ................................................................................................................................ 10- 4Cooling system .................................................................................................................... 10- 5Cooling fan motor................................................................................................................. 10- 6
Power train.............................................................................................................................. 10- 11Power train........................................................................................................................... 10- 11Hydraulic piping drawing of torque converter and transmission .......................................... 10- 13Torque converter.................................................................................................................. 10- 15Main relief valve and torque converter relief valve............................................................... 10- 24Torque converter regulator valve ......................................................................................... 10- 27ECMV................................................................................................................................... 10- 29Transmission........................................................................................................................ 10- 35Transmission control valve .................................................................................................. 10- 46Transmission lubricating oil relief valve ............................................................................... 10- 56Transfer................................................................................................................................ 10- 57Torque converter oil cooler .................................................................................................. 10- 59Center support ..................................................................................................................... 10- 60Axle ...................................................................................................................................... 10- 61Final drive ............................................................................................................................ 10- 66
Steering system ...................................................................................................................... 10- 67Steering equipment layout drawing...................................................................................... 10- 67AJSS.................................................................................................................................... 10- 68Steering pump...................................................................................................................... 10- 70Switch pump ........................................................................................................................ 10- 72Steering demand valve ........................................................................................................ 10- 89Rotary valve ......................................................................................................................... 10- 99EPC valve (for steering)....................................................................................................... 10- 102
00-2
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Table of Contents
WA1200-6
Diverter valve....................................................................................................................... 10- 103Emergency steering relief valve........................................................................................... 10- 106Steering lock valve............................................................................................................... 10- 107
Brake system .......................................................................................................................... 10- 108Brake equipment layout drawing ......................................................................................... 10- 108Brake valve .......................................................................................................................... 10- 109Charge valve........................................................................................................................ 10- 115Accumulator (for brake) ....................................................................................................... 10- 119Slack adjuster ...................................................................................................................... 10- 120Brake ................................................................................................................................... 10- 122Parking brake....................................................................................................................... 10- 123Parking brake solenoid valve............................................................................................... 10- 124Emergency parking brake release valve.............................................................................. 10- 125Check valve of parking brake circuit .................................................................................... 10- 126
Undercarriage and frame........................................................................................................ 10- 129Axle mount........................................................................................................................... 10- 129Center hinge pin .................................................................................................................. 10- 131Jack-up point ....................................................................................................................... 10- 132
Hydraulic system .................................................................................................................... 10- 133Hydraulic piping layout drawing ........................................................................................... 10- 133Work equipment control lever linkage.................................................................................. 10- 135Hydraulic tank ...................................................................................................................... 10- 136Work equipment pump No.1 ................................................................................................ 10- 139Work equipment pump No.2 ................................................................................................ 10- 152EPC valve (for work equipment) .......................................................................................... 10- 175Neutral cutoff solenoid valve (NC valve).............................................................................. 10- 177Relief valve .......................................................................................................................... 10- 179Accumulator (for EPC valve) ............................................................................................... 10- 180Work equipment control valve ............................................................................................. 10- 181
Work equipment...................................................................................................................... 10- 194Work equipment linkage ...................................................................................................... 10- 194
Electrical system..................................................................................................................... 10- 196Machine monitor system...................................................................................................... 10- 196Multi-function monitor .......................................................................................................... 10- 224Work equipment and AJSS control system ......................................................................... 10- 277Work equipment control lever .............................................................................................. 10- 312Transmission control system ............................................................................................... 10- 315Engine starting circuit .......................................................................................................... 10- 341Engine stopping circuit......................................................................................................... 10- 343Electric parking brake control .............................................................................................. 10- 347Sensor ................................................................................................................................. 10- 357
20 Standard value tableStandard value table............................................................................................................... 20- 3
Standard value table for engine........................................................................................... 20- 3Standard value table for chassis.......................................................................................... 20- 4
30 Testing and adjustingTool for testing, adjusting and troubleshooting ....................................................................... 30- 4
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 4Safety precautions to follow before starting work ................................................................ 30- 9
Engine and cooling system..................................................................................................... 30- 13Testing engine speed .......................................................................................................... 30- 13Testing exhaust gas color.................................................................................................... 30- 15
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Testing blow-by pressure..................................................................................................... 30- 16Measuring engine oil pressure............................................................................................. 30- 17Measuring exhaust gas temperature ................................................................................... 30- 18Testing intake air pressure (boost pressure) ....................................................................... 30- 19Testing radiator performance............................................................................................... 30- 20Measuring wind speed across radiator and oil cooler.......................................................... 30- 21Testing and adjusting fan belt tension ................................................................................. 30- 22Testing and adjusting air conditioner compressor belt tension ............................................ 30- 23
Power train.............................................................................................................................. 30- 24Adjusting speed sensor........................................................................................................ 30- 24Testing and adjusting torque converter and transmission oil pressure................................ 30- 26Traction control function checking procedure ...................................................................... 30- 29Testing torque converter oil cooler performance ................................................................. 30- 30Testing additional cooler fan speed ..................................................................................... 30- 31Flushing procedure for torque converter and transmission circuit ....................................... 30- 32Retrieval of disabled machine due to transmission valve failure ......................................... 30- 33How to measure play of center hinge bearing ..................................................................... 30- 36Measuring wear of rear axle support ................................................................................... 30- 38
Steering system ...................................................................................................................... 30- 39Testing and adjusting steering oil pressure ......................................................................... 30- 39Testing and adjusting emergency steering oil pressure....................................................... 30- 40Bleeding air from steering circuit.......................................................................................... 30- 42Testing and adjusting steering stopper bolt ......................................................................... 30- 44Adjusting steering follow-up linkage..................................................................................... 30- 45Testing steering EPC valve.................................................................................................. 30- 50Testing and adjusting steering surge cut valve oil pressure ................................................ 30- 52Testing and adjusting steering main relief valve oil pressure .............................................. 30- 54Testing rotary valve output pressure.................................................................................... 30- 56
Brake system .......................................................................................................................... 30- 58Testing brake performance .................................................................................................. 30- 58Testing lowering of wheel brake oil pressure....................................................................... 30- 59Testing of slack adjuster ...................................................................................................... 30- 60Mesuring wear of wheel brake disc...................................................................................... 30- 61Testing and adjusting accumulator charge pressure ........................................................... 30- 62Testing brake accumulator oil pressure leakage ................................................................. 30- 64Testing emergency parking brake valve oil leakage amount ............................................... 30- 66Testing brake valve oil leakage amount............................................................................... 30- 69Testing brake cooling oil pressure ....................................................................................... 30- 74Testing brake oil cooler performance................................................................................... 30- 76Testing parking brake performance ..................................................................................... 30- 76Testing wear of parking brake disc ...................................................................................... 30- 77Method of releasing parking brake manually ....................................................................... 30- 78Testing parking brake oil pressure....................................................................................... 30- 79Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ......................................................................................................................... 30- 80
Hydraulic system..................................................................................................................... 30- 86Testing and adjusting work equipment oil pressure by using multi monitor......................... 30- 86Testing and adjusting work equipment oil pressure by using oil pressure gauge................ 30- 88Testing and adjusting work equipment PPC oil pressure .................................................... 30- 89Measuring point of hydraulic pump oil pressure .................................................................. 30- 91Testing and adjusting PV control relief valve oil pressure ................................................... 30- 95Testing and adjusting differential valve output oil pressure ................................................. 30- 97Testing work pump ES valve output pressure ..................................................................... 30- 99Testing and adjusting work pump CO (cut-off) valve oil pressure ....................................... 30- 101
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WA1200-6
Testing and adjusting work equipment pump TVC valve oil pressure ................................. 30- 105Operation test of work equipment valve by work equipment speed (speed of work equipment is low)................................................................................................................. 30- 107Testing hydraulic oil cooler performance ............................................................................. 30- 114Bleeding air from hydraulic circuit ........................................................................................ 30- 117Releasing remaining pressure in hydraulic circuit ............................................................... 30- 122
Work equipment...................................................................................................................... 30- 123Checking center hinge pin lubrication.................................................................................. 30- 123Adjustment method of auto grease injector delivery............................................................ 30- 125Setting method of auto grease timer.................................................................................... 30- 126
Electrical system..................................................................................................................... 30- 128Testing and adjusting bucket proximity switch..................................................................... 30- 128Adjusting lift arm potentiometer ........................................................................................... 30- 129Adjusting lift arm levelness detecting switch........................................................................ 30- 130Initial setting procedure for remote boom positioner (origin input method).......................... 30- 131Checking proximity switch operation pilot lamp ................................................................... 30- 132Adjusting AJSS lever angle sensor and frame angle sensor............................................... 30- 133Testing and adjusting potentiometer mounting position ...................................................... 30- 134Procedure for testing diodes................................................................................................ 30- 137Basic precautions for KOMTRAX Plus controller................................................................. 30- 138Inspection and maintenance of KOMTRAX Plus controller ................................................. 30- 147Initial setting procedure for KOMTRAX Plus controller ........................................................ 30- 148Precautions for replacing KOMTRAX Plus controller .......................................................... 30- 165Measurement procedure by downloading data in KOMTRAX Plus controller ..................... 30- 173Measurement procedure by multi monitor ........................................................................... 30- 177Special functions of multi monitor ........................................................................................ 30- 179
Pm Clinic................................................................................................................................. 30- 236Outline of measurement procedure for Pm Clinic................................................................ 30- 236Preparation for measurement for Pm Clinic......................................................................... 30- 237Pm clinic service .................................................................................................................. 30- 238
40 TroubleshootingGeneral information on troubleshooting.................................................................................. 40- 8
Symptom and troubleshooting numbers .............................................................................. 40- 8Sequence of events in troubleshooting................................................................................ 40- 9Check before troubleshooting.............................................................................................. 40- 10Classification and procedures of troubleshooting ................................................................ 40- 21Breakage of hydraulic cylinder............................................................................................. 40- 24Failure codes table .............................................................................................................. 40- 27Symptom and troubleshooting numbers .............................................................................. 40- 43Information in troubleshooting table..................................................................................... 40- 44Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 46Layout drawing of connector pins ........................................................................................ 40- 48Connector list and layout ..................................................................................................... 40- 84T- branch box and T- branch adapter table ......................................................................... 40- 104Table of fuse locations......................................................................................................... 40- 107
Troubleshooting by failure code.............................................................................................. 40- 110Failure code [1500L0] Double Engagement of Transmission Clutches............................... 40- 110Failure code [1540N1] T/M overrun ..................................................................................... 40- 111Failure code [15B0NX] T/M Oil Filter Clogged..................................................................... 40- 112Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit .................................................. 40- 114Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect ......................................... 40- 116Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit .................................................. 40- 118Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect......................................... 40- 120
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WA1200-6
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit................................................... 40- 122Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect.......................................... 40- 124Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit ................................................... 40- 126Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect.......................................... 40- 128Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit .................................................. 40- 130Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect ......................................... 40- 132Failure code [2F00MA] Parking brake circuit failure ............................................................ 40- 135Failure code [2G42ZG] Accumulator Oil Press. F Low ........................................................ 40- 138Failure code [2G43ZG] Accumulator Oil Press. R Low........................................................ 40- 140Failure code [44K0L4] Bucket cylinder position detector SW failure ................................... 40- 142Failure code [7REAKA] ACC Signal Malfunction ................................................................. 40- 143Failure code [989P00] Direction protection warning ............................................................ 40- 144Failure code [989Q00] Work equipment protection ............................................................. 40- 144Failure code [989R00] Tire slip ............................................................................................ 40- 145Failure code [989S00] Parking Brake Dragging................................................................... 40- 146Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF).................................. 40- 148Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) ................................... 40- 149Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) ................................... 40- 150Failure code [989W00] Stationary steering (Brake: ON, Load: ON) .................................... 40- 151Failure code [AA1ANX] Air Cleaner 1 Clogging................................................................... 40- 152Failure code [AA1BNX] Air Cleaner 2 Clogging................................................................... 40- 154Failure code [AA1CNX] Air Cleaner 3 Clogging................................................................... 40- 156Failure code [AA1DNX] Air Cleaner 4 Clogging................................................................... 40- 158Failure code [AB00L6] Discharge of alternator R terminal................................................... 40- 160Failure code [AB00MA] Discharge of alternator R terminal ................................................. 40- 162Failure code [AB00MB] Discharge of alternator R terminal ................................................. 40- 164Failure code [B@BCZK] Drop in Engine Coolant Level....................................................... 40- 166Failure code [b@C5ZK] Low brake fluid level (before engine start) .................................... 40- 168Failure code [B@C5ZK] Low brake fluid level (while engine is running) ............................. 40- 169Failure code [B@C6NS] High brake oil temp....................................................................... 40- 170Failure code [b@CENS] High torque converter oil temp. .................................................... 40- 171Failure code [B@CENS] Very high torque converter oil temp. ............................................ 40- 172Failure code [B@GAZK] Low battery 1 fluid level................................................................ 40- 174Failure code [B@GBZK] Low battery 2 fluid level................................................................ 40- 176Failure code [B@GCZK] Low battery 3 fluid level................................................................ 40- 178Failure code [B@HANS] High hydraulic oil temp................................................................. 40- 180Failure code [B@HAZK] Low hydraulic oil level................................................................... 40- 181Failure code [D191KA] Neutral Output Relay Disconnection............................................... 40- 182Failure code [D191KB] Neutral Output Relay hot short ....................................................... 40- 184Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit) ............ 40- 186Failure code [D19MKY] SW pump PNC solenoid Relay hot short ....................................... 40- 188Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure ...................................... 40- 190Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure ...................................... 40- 192Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)............. 40- 194Failure code [D5ZHKB] Starting Switch C signal circuit Hot short ....................................... 40- 196Failure code [D5ZHKZ] Starting Switch C signal circuit failure ............................................ 40- 198Failure code [D5ZHL6] Ignition C terminal Circuit Failure.................................................... 40- 200Failure code [DAF5KP] Monitor Panel 5 V source sys Error ............................................... 40- 202Failure code [DAFRKR] Communication Lost Monitor Panel Controller.............................. 40- 204Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source.................... 40- 206Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal.................................... 40- 208Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source ............. 40- 210Failure code [DAQRKR] Communication Lost T/M Controller ............................................. 40- 212Failure code [DAQRMA] Defective Option Selection Data in Transmission ........................ 40- 214
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WA1200-6
Failure code [DB2RKR] Communication Lost Engine Controller......................................... 40- 216Failure code [DB90KK] Drop in Work Controller Main Power Source ................................. 40- 218Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal .................................... 40- 220Failure code [DB92KK] Solenoid Voltage Failure (Work controller) .................................... 40- 222Failure code [DB95KX] 5 V source sys Error (Work controller) ........................................... 40- 224Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller ............ 40- 226Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller ........ 40- 228Failure code [DB9RMC] Communication Lost (Work Controller)......................................... 40- 230Failure code [DBB0KK] VHMS source voltage Error ........................................................... 40- 232Failure code [DBB0KQ] VHMS Connector Mismatch .......................................................... 40- 234Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT
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WA1200-6
Failure code [DHT5KX] Torque converter intake pressure sensor circuit............................ 40- 322Failure code [DHT8KX] Steering Oil Press. Sensor Failure................................................. 40- 324Failure code [DHTAKX] Transmission lubrication pressure sensor circuit........................... 40- 326Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect................... 40- 328Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit .................. 40- 330Failure code [DHU2KA] F Brake Oil press Sensor Disconnect............................................ 40- 332Failure code [DHU2KB] F Brake Oil press Sensor Hot short............................................... 40- 334Failure code [DHU2KX] F Brake Oil press Sensor Failure .................................................. 40- 336Failure code [DHU3KA] R Brake Oil press Sensor Disconnect ........................................... 40- 338Failure code [DHU3KB] R Brake Oil press Sensor Hot short .............................................. 40- 340Failure code [DHU3KX] R Brake Oil press Sensor Failure .................................................. 40- 341Failure code [DJF1KA] Fuel level sensor circuit Disconnection........................................... 40- 343Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit).................. 40- 344Failure code [DK30KY] Steering lever angle sensor circuit hot short .................................. 40- 345Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit) ......... 40- 346Failure code [DK59KY] Boom lever potentiometer (main) hot short .................................... 40- 348Failure code [DK59L8] Boom lever potentiometer (main & sub) failure............................... 40- 349Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)........... 40- 352Failure code [DK5AKY] Boom lever potentiometer (sub) hot short...................................... 40- 354Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit) ....... 40- 356Failure code [DK5BKY] Bucket lever potentiometer (main) hot short .................................. 40- 358Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure............................. 40- 359Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)......... 40- 362Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short.................................... 40- 363Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) .............................. 40- 364Failure code [DKA0KX] Boom angle sensor circuit failure................................................... 40- 366Failure code [DKA0KY] Boom angle sensor circuit hot short............................................... 40- 368Failure code [DKA0L0] Boom angle sensor failure .............................................................. 40- 370Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)............................. 40- 372Failure code [DKD0KY] Frame angle sensor circuit hot short ............................................. 40- 373Failure code [DKD0KZ] Frame and steering angle sensor failure ....................................... 40- 374Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect ............................................ 40- 375Failure code [DKH0KB] Angle sensor circuit (FR) Hot short................................................ 40- 376Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect............................................. 40- 378Failure code [DKH1KB] Angle sensor circuit (LR) Hot short................................................ 40- 380Failure code [DLE2KA] Engine Speed Sensor Disconnection............................................. 40- 382Failure code [DLE2LC] Engine Speed Sensor Short Circuit................................................ 40- 384Failure code [DLF6LC] Tire speed sensor circuit................................................................. 40- 386Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect ....................................... 40- 388Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit ..................................... 40- 390Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit ................................. 40- 392Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection............................... 40- 394Failure code [DT20KB] Transmission cut off indicator Output short circuit.......................... 40- 396Failure code [DT21KB] Speed Control indicator Output short circuit................................... 40- 397Failure code [DUM8KB] VHMS Operation lamp Short Circuit ............................................. 40- 398Failure code [DV00KY] Buzzer circuit hotshort (for usually) ................................................ 40- 400Failure code [DV01KY] Buzzer circuit hotshort (for special) ................................................ 40- 402Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection......................... 40- 404Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit............................ 40- 405Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short ...................... 40- 406Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection ........................ 40- 407Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit ........................... 40- 408Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short ...................... 40- 409Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection ...................... 40- 410
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WA1200-6
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit ......................... 40- 411Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short.................... 40- 412Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection ................................. 40- 413Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault .................................. 40- 414Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short ....................................... 40- 415Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection .............................. 40- 416Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit ............................ 40- 417Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short ................................ 40- 418Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection................................... 40- 419Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault ...................................... 40- 420Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short ........................................... 40- 421Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection ................................. 40- 422Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit ................................. 40- 423Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...................................... 40- 424Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection ................................. 40- 425Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault .................................. 40- 426Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short ....................................... 40- 427Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection ........................ 40- 428Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault ................................. 40- 429Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short ...................................... 40- 430Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection ...................................... 40- 431Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault ........................................... 40- 432Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short .............................................. 40- 433Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection ................................. 40- 434Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit..................................... 40- 435Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short ......................................... 40- 436Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection............................ 40- 437Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit............................... 40- 438Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short ......................... 40- 439Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection .................. 40- 440Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit ...................... 40- 441Failure code [DWM1KY] Work equipment neutral lock solenoid hot short .......................... 40- 442Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection.................... 40- 443Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit ....................... 40- 444Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short............................ 40- 445Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection..................... 40- 446Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit ........................ 40- 447Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short............................. 40- 448Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection ...................... 40- 449Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit ........................... 40- 450Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short ................................ 40- 451Failure code [DWNAKA] NC solenoid disconnection........................................................... 40- 452Failure code [DWNAKB] NC solenoid short circuit .............................................................. 40- 453Failure code [DWNAKY] NC solenoid hot short................................................................... 40- 454Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit) ............... 40- 455Failure code [DXA1KY] Loader pump solenoid Relay hot short .......................................... 40- 457Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit) .............. 40- 459Failure code [DXF0KA] AJSS EPC solenoid disconnection ................................................ 40- 461Failure code [DXF0KB] AJSS EPC solenoid short circuit .................................................... 40- 463Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection................................... 40- 465Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit...................................... 40- 467Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short ................................ 40- 469Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection.................................. 40- 471Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit .................................... 40- 473
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Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short ............................... 40- 475Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection................................... 40- 477Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit ..................................... 40- 479Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short ................................ 40- 481Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection ..................................... 40- 483Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit ........................................ 40- 485Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short................................... 40- 487Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection...................................... 40- 489Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit ........................................ 40- 491Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short ................................... 40- 493Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection ........................... 40- 494Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit .............................. 40- 495Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V.................. 40- 496Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction ............................... 40- 497
Troubleshooting of electrical system (E-mode),...................................................................... 40- 499E-1 Remote positioner "RAISE" or "LOWER" LED does not light up................................... 40- 499E-2 Open circuit or ground fault in check lamp system........................................................ 40- 500E-3 Machine monitor does not operate................................................................................ 40- 501E-4 Turn signal lamp does not light up ................................................................................ 40- 502E-5 Defective parking lamp.................................................................................................. 40- 504E-6 Defective front working lamp ......................................................................................... 40- 506E-7 Defective rear working lamp.......................................................................................... 40- 508E-8 Headlamp does not light up........................................................................................... 40- 510E-9 Service meter does not work, or service meter works while engine is stopped. ........... 40- 512E-10 Monitor panel controller does not sound buzzer ......................................................... 40- 514E-11 Defective auto-greasing system .................................................................................. 40- 516
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 518Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor) ....................................................................................................................... 40- 518Work equipment hydraulic system, general ......................................................................... 40- 528Work equipment oil pressure group ..................................................................................... 40- 530Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)................................................................................................................................ 40- 595Checking steering related standard values.......................................................................... 40- 608Steering oil pressure system, general.................................................................................. 40- 609Steering oil pressure group.................................................................................................. 40- 610Brake oil pressure system, general...................................................................................... 40- 650Brake oil pressure group...................................................................................................... 40- 651Information contained in troubleshooting table (H mode) .................................................... 40- 701H-1 Torque converter oil temperature rises too high (overheats) ........................................ 40- 702H-2 Turning or response of steering is poor ........................................................................ 40- 705H-3 AJSS lever is hard to operate ....................................................................................... 40- 708H-4 Steering shakes or jolts................................................................................................. 40- 710H-5 Wheel brake does not work at all or is weak................................................................. 40- 712H-6 Lift arm speed is low or lift arm rising force is insufficient ............................................. 40- 714H-7 Shock is large when lift arm stops................................................................................. 40- 717H-8 Hydraulic oil temperature rises too high (overheating).................................................. 40- 718
50 Disassembly and assemblyGeneral information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4Coating materials list............................................................................................................ 50- 6Special tool list ..................................................................................................................... 50- 9Sketches of special tools ..................................................................................................... 50- 14
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WA1200-6
Flushing procedure ................................................................................................................. 50- 54Flushing procedure for brake circuit .................................................................................... 50- 54Flushing procedure for work equipment and steering circuit ............................................... 50- 60
Air bleeding procedure............................................................................................................ 50- 66Bleeding air from brake circuit ............................................................................................. 50- 66Bleeding air from piston pump ............................................................................................. 50- 68Bleeding air from work equipment circuit and steering circuit.............................................. 50- 69
Engine and cooling system..................................................................................................... 50- 72Removal and installation of radiator and hydraulic oil cooler assembly .............................. 50- 72Removal and installation of engine assembly...................................................................... 50- 79Removal and installation of air-cooled torque converter and transmission,
and brake oil cooler assembly .............................................................................. 50- 86Removal and installation of water-cooled torque converter and transmission
oil cooler assembly ............................................................................................... 50- 88Removal and installation of damper assembly .................................................................... 50- 89Disassembly and assembly of damper ................................................................................ 50- 91Removal and installation of bumper and fuel tank assembly............................................... 50- 98Removal and installation of hood assembly ........................................................................ 50- 100Disassembly and assembly procedures for MESABI oil cooler ........................................... 50- 102Disassembly and assembly of MESABI oil cooler ............................................................... 50- 105
Power train.............................................................................................................................. 50- 113Removal and installation of torque converter and transmission assembly .......................... 50- 113Disconnection and connection of transmission assembly and torque converter assembly . 50- 120Disconnection and connection of torque converter assembly, PTO and transfer assembly 50- 127Disassembly and assembly of torque converter .................................................................. 50- 131Disassembly and assembly of modulation clutch ................................................................ 50- 142Disassembly and assembly of PTO and transfer................................................................. 50- 146Disconnection and connection of transmission assembly, transfer, and parking
brake assembly .................................................................................................... 50- 159Disassembly and assembly of transmission assembly........................................................ 50- 166Disassembly and assembly of transfer ................................................................................ 50- 187Disassembly and assembly of parking brake ...................................................................... 50- 194Removal and installation of parking brake assembly (installed on the machine) ................ 50- 197Removal and installation of transmission, brake cooling device and brake pump assembly 50- 201Removal and installation of steering pump, control pump and PPC pump assembly ......... 50- 202Disassembly and assembly of drive shaft............................................................................ 50- 203Removal and installation of front axle assembly.................................................................. 50- 205Removal and installation of front final drive assembly......................................................... 50- 207Removal and installation of rear axle assembly .................................................................. 50- 209Removal and installation of rear final drive assembly.......................................................... 50- 220Removal and installation of differential assembly................................................................ 50- 223Disassembly and assembly of differential............................................................................ 50- 225Disassembly and assembly of final drive and brake............................................................ 50- 238Removal and installation of center support assembly ......................................................... 50- 251Disassembly and assembly of center support ..................................................................... 50- 253
Steering system ...................................................................................................................... 50- 257Removal and installation of steering demand valve assembly ............................................ 50- 257Removal and installation of steering cylinder assembly ...................................................... 50- 258Removal and installation of emergency diverter valve assembly ........................................ 50- 262Removal and installation of emergency steering pump assembly....................................... 50- 264
Brake system .......................................................................................................................... 50- 265Removal and installation of brake accumulator charge valve assembly ............................. 50- 265Removal and installation of brake oil tank assembly ........................................................... 50- 266
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Table of Contents
WA1200-6
Undercarriage and frame ........................................................................................................ 50- 267Procedure for disconnecting front frame and rear frame ..................................................... 50- 267Removal and installation of center hinge pin ....................................................................... 50- 268
Hydraulic system..................................................................................................................... 50- 284Removal and installation of hydraulic tank, filter case assembly ......................................... 50- 284Removal and installation of No. 1 work equipment pump assembly.................................... 50- 286Removal and installation of No. 2 work equipment pump assembly.................................... 50- 288Removal and installation of switch pump assembly............................................................. 50- 289Removal and installation of work equipment control valve assembly .................................. 50- 290
Work equipment...................................................................................................................... 50- 304Removal and installation of bucket cylinder assembly......................................................... 50- 304Removal and installation of lift cylinder assembly................................................................ 50- 315Disassembly and assembly of work equipment cylinder...................................................... 50- 329Removal and installation of work equipment assembly ....................................................... 50- 335Procedure for running in bucket pin ..................................................................................... 50- 391Procedure for running in lift arm pin..................................................................................... 50- 393
Cab ......................................................................................................................................... 50- 396Removal and installation of bulkhead assembly .................................................................. 50- 396Removal and installation of operator's cab and floor assembly ........................................... 50- 398Removal and installation of operator's cab assembly .......................................................... 50- 402Removal and installation of air conditioner unit assembly ................................................... 50- 404Disassembly and assembly of operator seat ....................................................................... 50- 406
Electrical system ..................................................................................................................... 50- 439Removal and installation of DT connector pin ..................................................................... 50- 439Removal and installation of HD connector pin ..................................................................... 50- 441Repairing HD connector pin harness ................................................................................... 50- 442Removal and installation of controller assembly.................................................................. 50- 443
60 Maintenance standardEngine and cooling system ..................................................................................................... 60- 3
Engine mount....................................................................................................................... 60- 3Cooling system .................................................................................................................... 60- 4Cooling fan motor................................................................................................................. 60- 5Damper ................................................................................................................................ 60- 7
Power train.............................................................................................................................. 60- 8Transmission mount............................................................................................................. 60- 8Torque converter.................................................................................................................. 60- 10Main relief valve, torque converter relief valve..................................................................... 60- 14Torque converter regulator valve ......................................................................................... 60- 16ECMV................................................................................................................................... 60- 17Transmission........................................................................................................................ 60- 18Transmission control valve .................................................................................................. 60- 20Lubrication relief valve ......................................................................................................... 60- 23Transfer................................................................................................................................ 60- 24Torque converter pump, transmission pump, brake cooling pump, brake pump ................. 60- 26Drive shaft............................................................................................................................ 60- 28Center support ..................................................................................................................... 60- 30Differential............................................................................................................................ 60- 32Final drive ............................................................................................................................ 60- 36
Steering system ...................................................................................................................... 60- 38Steering pump...................................................................................................................... 60- 38Switch pump ........................................................................................................................ 60- 39Steering demand valve ........................................................................................................ 60- 41Diverter valve ....................................................................................................................... 60- 43
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WA1200-6
Steering cylinder mount ....................................................................................................... 60- 44Steering cylinder .................................................................................................................. 60- 45Emergency steering pump................................................................................................... 60- 47
Brake system .......................................................................................................................... 60- 48Brake valve .......................................................................................................................... 60- 48Slack adjuster ...................................................................................................................... 60- 50Brake ................................................................................................................................... 60- 51Parking brake....................................................................................................................... 60- 52
Undercarriage and frame........................................................................................................ 60- 54axle mount ........................................................................................................................... 60- 54Center hinge pin .................................................................................................................. 60- 56
Hydraulic system .................................................................................................................... 60- 59No.1 work equipment pump................................................................................................. 60- 59No.2 work equipment pump................................................................................................. 60- 62PPC relief valve ................................................................................................................... 60- 65Pump control relief valve ..................................................................................................... 60- 66Work equipment control valve ............................................................................................. 60- 67
Work equipment...................................................................................................................... 60- 69Work equipment linkage ...................................................................................................... 60- 69Bucket positioner, remote positioner ................................................................................... 60- 74Work equipment cylinder ..................................................................................................... 60- 75
Electrical system..................................................................................................................... 60- 77Work equipment control lever .............................................................................................. 60- 77
80 AppendixAir conditioner......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3Configuration and function of refrigeration cycle ................................................................. 80- 4Outline of refrigeration cycle ................................................................................................ 80- 5Control system..................................................................................................................... 80- 7Air conditioner components ................................................................................................. 80- 11Compressor ......................................................................................................................... 80- 18Electric fan and condenser .................................................................................................. 80- 19Receiver drier ...................................................................................................................... 80- 21Service tools ........................................................................................................................ 80- 22Troubleshooting procedures ................................................................................................ 80- 29Interview and confirmation of failure symptom .................................................................... 80- 30Basic checks........................................................................................................................ 80- 31Troubleshooting ................................................................................................................... 80- 32Checking of refrigeration cycle ............................................................................................ 80- 38Troubleshooting for unusual noise....................................................................................... 80- 46Electrical system.................................................................................................................. 80- 47Parts replacement................................................................................................................ 80- 49Periodic inspection and maintenance .................................................................................. 80- 52Testing and adjusting compressor belt tension ................................................................... 80- 56
90 Diagrams and drawingsHydraulic circuit diagram ........................................................................................................ 90- 3
Circuit symbols used in hydraulic circuit diagrams .............................................................. 90- 3Transmission hydraulic circuit diagram................................................................................ 90- 6Brake hydraulic circuit diagram............................................................................................ 90- 8Work equipment hydraulic circuit diagram........................................................................... 90- 11
Electrical circuit diagram......................................................................................................... 90- 15Circuit symbols used in electrical circuit diagrams .............................................................. 90- 15
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WA1200-6
Electrical circuit diagram ...................................................................................................... 90- 19
Index ....................................................................................................................................... 1
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WA1200-6 00-15
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Foreword and general informationSafety notice
WA1200-6
Foreword and general information 00-16Safety notice 00-16
Important safety notice
Appropriate servicing and repair are extremely important to ensure safe operation of the machine.The shop manuals describe the effective and safe servicing and repair methods recommended by Ko-matsu. Some of the servicing and repair methods require use of special tools designed by Komatsufor special purposes.The symbol mark "k" is indicated for such matters that require special precautions. The work indi-cated with the warning mark should be performed according to the instructions with special attentionto the precautions. Should a hazardous situation occur or be anticipated during such work, be sureto keep safe first and take every necessary measure.
1. General precautionskInappropriate handling creates an extreme
danger. Read and understand what is de-scribed in the Operation and MaintenanceManual before operating the machine.Read and understand what is described inthis manual before starting work.
1)Before performing any greasing or repairs,read all the safety labels stuck to themachine. For the locations of the safetylabels and detailed explanation of precau-tions, see the Operation and MaintenanceManual.
2)Locate a place in the repair workshop to keeptools and removed parts. Always keep thetools and parts in their correct places. Alwayskeep the work area clean and make sure thatthere is no dirt, water, or oil on the floor.Smoke only in the areas provided forsmoking. Never smoke while working.
3)When performing any operation, always wearsafety shoes and helmet. Do not wear loosework clothes, or clothes with buttons missing.qAlways wear the safety glasses when hitting
parts with a hammer.qAlways wear the safety glasses when grind-
ing parts with a grinder, etc.4)When performing any operation with two or
more workers, alway
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