wa1200-6 shop manual

WHEEL LOADER

SEN05475-01

WA1200-6SERIAL NUMBERS 60001 and up

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

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( ) Page to be deleted Discard

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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

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Notice of revision

2 WA1200-6(01)

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Revision number

WA1200-6 3(01)

Notice of revision

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Revision number

Notice of revision

4 WA1200-6(01)

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Revision number

WA1200-6 5(01)

Notice of revision

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Revision number

Notice of revision

6 WA1200-6(01)

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Revision number

WA1200-6 7(01)

Notice of revision

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Revision number

Notice of revision

8 WA1200-6(01)

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Revision number

WA1200-6 9(01)

Notice of revision

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Revision number

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



Revision number

WA1200-6 11(01)

Notice of revision

90-3690-3790-3890-3990-4090-4190-4290-4390-44

12345678

q Colophon (01)



Revision number

Notice of revision

12 WA1200-6(01)

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

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

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

00-3

Table of Contents

WA1200-6

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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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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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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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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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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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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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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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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Electrical circuit diagram ...................................................................................................... 90- 19

Index ....................................................................................................................................... 1

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WA1200-6 00-15

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

wa1200-6 shop manual

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