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Komatsu WA1200-6 Wheel Loader Service Repair Manual – PDF Download
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- Komatsu WA1200-6 Wheel Loader Service Repair Manual
- SERIAL NUMBERS 60001 and up
- PUBLICATION NUMBER:SEN05475
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Description
Komatsu WA1200-6 Wheel Loader Service Repair Manual
Description:
Komatsu WA1200-6 Wheel Loader Service Repair Manual
- This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
- 00. Index and foreword This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
- 01. Specification This section explains the specifications of the machine.
- 10. Structure and function This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
- 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
- 30. Testing and adjusting This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
- 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
- 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
- 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
- 80. Appendix This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
- 90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
- Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams.
- Engine volume This section explains the method of remanufacturing and repairing engine and replacing parts
Table of Contents:
Komatsu WA1200-6 Wheel Loader Service Repair Manual
COVER ................................................................................................................................................................. 1 00 Index and foreword.................................................................................................................................................. 15 Table of Contents.................................................................................................................................................. 16 Table of Contents.............................................................................................................................................. 16 Foreword and general information................................................................................................................................... 30 Safety notice.................................................................................................................................................. 30 How to read the shop manual.................................................................................................................................... 35 Explanation of terms for maintenance standard.................................................................................................................. 37 Handling of hydraulic components............................................................................................................................... 39 Method of disconnecting and connecting push-pull type coupler.................................................................................................. 41 Handling of electric equipment................................................................................................................................. 44 How to read electric wire code................................................................................................................................. 54 Precautions when performing work............................................................................................................................... 57 Standard tightening torque table............................................................................................................................... 60 List of abbreviation........................................................................................................................................... 64 Conversion table............................................................................................................................................... 68 01 Specification....................................................................................................................................................... 73 Specification...................................................................................................................................................... 75 Specification dimension drawing................................................................................................................................ 75 Specifications................................................................................................................................................. 76 Weight table................................................................................................................................................... 79 Table of fuel, coolant and lubricants.......................................................................................................................... 81 10 Structure and function.............................................................................................................................................. 83 Engine and cooling system.......................................................................................................................................... 86 Damper......................................................................................................................................................... 86 Cooling system................................................................................................................................................. 87 Cooling fan motor.............................................................................................................................................. 88 Power train........................................................................................................................................................ 93 Power train.................................................................................................................................................... 93 Hydraulic piping drawing of torque converter and transmission.................................................................................................. 95 Torque converter............................................................................................................................................... 97 Main relief valve and torque converter relief valve............................................................................................................ 106 Torque converter regulator valve............................................................................................................................... 109 ECMV........................................................................................................................................................... 111 Transmission................................................................................................................................................... 117 Transmission control valve..................................................................................................................................... 128 Transmission lubricating oil relief valve...................................................................................................................... 138 Transfer....................................................................................................................................................... 139 Torque converter oil cooler.................................................................................................................................... 141 Center support................................................................................................................................................. 142 Axle........................................................................................................................................................... 143 Final drive.................................................................................................................................................... 148 Steering system.................................................................................................................................................... 149 Steering equipment layout drawing.............................................................................................................................. 149 AJSS........................................................................................................................................................... 150 Steering pump.................................................................................................................................................. 152 Switch pump.................................................................................................................................................... 154 Steering demand valve.......................................................................................................................................... 171 Rotary valve................................................................................................................................................... 181 EPC valve (for steering)....................................................................................................................................... 184 Diverter valve................................................................................................................................................. 185 Emergency steering relief valve................................................................................................................................ 188 Steering lock valve............................................................................................................................................ 189 Brake system....................................................................................................................................................... 190 Brake equipment layout drawing................................................................................................................................. 190 Brake valve.................................................................................................................................................... 191 Charge valve................................................................................................................................................... 197 Accumulator (for brake)........................................................................................................................................ 201 Slack adjuster................................................................................................................................................. 202 Brake.......................................................................................................................................................... 204 Parking brake.................................................................................................................................................. 205 Parking brake solenoid valve................................................................................................................................... 206 Emergency parking brake release valve.......................................................................................................................... 207 Check valve of parking brake circuit........................................................................................................................... 208 Undercarriage and frame............................................................................................................................................ 211 Axle mount..................................................................................................................................................... 211 Center hinge pin............................................................................................................................................... 213 Jack-up point.................................................................................................................................................. 214 Hydraulic system................................................................................................................................................... 215 Hydraulic piping layout drawing................................................................................................................................ 215 Work equipment control lever linkage........................................................................................................................... 217 Hydraulic tank................................................................................................................................................. 218 Work equipment pump No.1....................................................................................................................................... 221 Work equipment pump No.2....................................................................................................................................... 234 EPC valve (for work equipment)................................................................................................................................. 257 Neutral cutoff solenoid valve (NC valve)....................................................................................................................... 259 Relief valve................................................................................................................................................... 261 Accumulator (for EPC valve).................................................................................................................................... 262 Work equipment control valve................................................................................................................................... 263 Work equipment..................................................................................................................................................... 276 Work equipment linkage......................................................................................................................................... 276 Electrical system.................................................................................................................................................. 278 Machine monitor system......................................................................................................................................... 278 Multi-function monitor......................................................................................................................................... 306 Work equipment and AJSS control system......................................................................................................................... 359 Work equipment control lever................................................................................................................................... 394 Transmission control system.................................................................................................................................... 397 Engine starting circuit........................................................................................................................................ 423 Engine stopping circuit........................................................................................................................................ 425 Electric parking brake control................................................................................................................................. 429 Sensor......................................................................................................................................................... 439 20 Standard value table................................................................................................................................................ 461 Standard value table............................................................................................................................................... 463 Standard value table for engine................................................................................................................................ 463 Standard value table for chassis............................................................................................................................... 464 30 Testing and adjusting............................................................................................................................................... 469 Tool for testing, adjusting and troubleshooting.................................................................................................................... 472 Tools for testing, adjusting, and troubleshooting.............................................................................................................. 472 Safety precautions to follow before starting work.............................................................................................................. 477 Engine and cooling system.......................................................................................................................................... 481 Testing engine speed........................................................................................................................................... 481 Testing exhaust gas color...................................................................................................................................... 483 Testing blow-by pressure....................................................................................................................................... 484 Measuring engine oil pressure.................................................................................................................................. 485 Measuring exhaust gas temperature.............................................................................................................................. 486 Testing intake air pressure (boost pressure)................................................................................................................... 487 Testing radiator performance................................................................................................................................... 488 Measuring wind speed across radiator and oil cooler............................................................................................................ 489 Testing and adjusting fan belt tension......................................................................................................................... 490 Testing and adjusting air conditioner compressor belt tension.................................................................................................. 491 Power train........................................................................................................................................................ 492 Adjusting speed sensor......................................................................................................................................... 492 Testing and adjusting torque converter and transmission oil pressure........................................................................................... 494 Traction control function checking procedure................................................................................................................... 497 Testing torque converter oil cooler performance................................................................................................................ 498 Testing additional cooler fan speed............................................................................................................................ 499 Flushing procedure for torque converter and transmission circuit............................................................................................... 500 Retrieval of disabled machine due to transmission valve failure................................................................................................ 501 How to measure play of center hinge bearing.................................................................................................................... 504 Measuring wear of rear axle support............................................................................................................................ 506 Steering system.................................................................................................................................................... 507 Testing and adjusting steering oil pressure.................................................................................................................... 507 Testing and adjusting emergency steering oil pressure.......................................................................................................... 508 Bleeding air from steering circuit............................................................................................................................. 510 Testing and adjusting steering stopper bolt.................................................................................................................... 512 Adjusting steering follow-up linkage........................................................................................................................... 513 Testing steering EPC valve..................................................................................................................................... 518 Testing and adjusting steering surge cut valve oil pressure.................................................................................................... 520 Testing and adjusting steering main relief valve oil pressure.................................................................................................. 522 Testing rotary valve output pressure........................................................................................................................... 524 Brake system....................................................................................................................................................... 526 Testing brake performance...................................................................................................................................... 526 Testing lowering of wheel brake oil pressure................................................................................................................... 527 Testing of slack adjuster...................................................................................................................................... 528 Mesuring wear of wheel brake disc.............................................................................................................................. 529 Testing and adjusting accumulator charge pressure.............................................................................................................. 530 Testing brake accumulator oil pressure leakage................................................................................................................. 532 Testing emergency parking brake valve oil leakage amount....................................................................................................... 534 Testing brake valve oil leakage amount......................................................................................................................... 537 Testing brake cooling oil pressure............................................................................................................................. 542 Testing brake oil cooler performance........................................................................................................................... 544 Testing parking brake performance.............................................................................................................................. 544 Testing wear of parking brake disc............................................................................................................................. 545 Method of releasing parking brake manually..................................................................................................................... 546 Testing parking brake oil pressure............................................................................................................................. 547 Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas............................................................. 548 Hydraulic system................................................................................................................................................... 554 Testing and adjusting work equipment oil pressure by using multi monitor....................................................................................... 554 Testing and adjusting work equipment oil pressure by using oil pressure gauge.................................................................................. 556 Testing and adjusting work equipment PPC oil pressure.......................................................................................................... 557 Measuring point of hydraulic pump oil pressure................................................................................................................. 559 Testing and adjusting PV control relief valve oil pressure..................................................................................................... 563 Testing and adjusting differential valve output oil pressure................................................................................................... 565 Testing work pump ES valve output pressure..................................................................................................................... 567 Testing and adjusting work pump CO (cut-off) valve oil pressure................................................................................................ 569 Testing and adjusting work equipment pump TVC valve oil pressure............................................................................................... 573 Operation test of work equipment valve by work equipment speed (speed of work equipment is low)................................................................ 575 Testing hydraulic oil cooler performance....................................................................................................................... 582 Bleeding air from hydraulic circuit............................................................................................................................ 585 Releasing remaining pressure in hydraulic circuit.............................................................................................................. 590 Work equipment..................................................................................................................................................... 591 Checking center hinge pin lubrication.......................................................................................................................... 591 Adjustment method of auto grease injector delivery............................................................................................................. 593 Setting method of auto grease timer............................................................................................................................ 594 Electrical system.................................................................................................................................................. 596 Testing and adjusting bucket proximity switch.................................................................................................................. 596 Adjusting lift arm potentiometer............................................................................................................................... 597 Adjusting lift arm levelness detecting switch.................................................................................................................. 598 Initial setting procedure for remote boom positioner (origin input method)..................................................................................... 599 Checking proximity switch operation pilot lamp................................................................................................................. 600 Adjusting AJSS lever angle sensor and frame angle sensor....................................................................................................... 601 Testing and adjusting potentiometer mounting position.......................................................................................................... 602 Procedure for testing diodes................................................................................................................................... 605 Basic precautions for KOMTRAX Plus controller.................................................................................................................. 606 Inspection and maintenance of KOMTRAX Plus controller.......................................................................................................... 615 Initial setting procedure for KOMTRAX Plus controller.......................................................................................................... 616 Precautions for replacing KOMTRAX Plus controller.............................................................................................................. 633 Measurement procedure by downloading data in KOMTRAX Plus controller........................................................................................... 641 Measurement procedure by multi monitor......................................................................................................................... 645 Special functions of multi monitor............................................................................................................................. 647 Pm Clinic.......................................................................................................................................................... 704 Outline of measurement procedure for Pm Clinic................................................................................................................. 704 Preparation for measurement for Pm Clinic...................................................................................................................... 705 Pm clinic service.............................................................................................................................................. 706 40 Troubleshooting..................................................................................................................................................... 711 General information on troubleshooting............................................................................................................................. 718 Symptom and troubleshooting numbers............................................................................................................................ 718 Sequence of events in troubleshooting.......................................................................................................................... 719 Check before troubleshooting................................................................................................................................... 720 Classification and procedures of troubleshooting............................................................................................................... 731 Breakage of hydraulic cylinder................................................................................................................................. 734 Failure codes table............................................................................................................................................ 737 Symptom and troubleshooting numbers............................................................................................................................ 753 Information in troubleshooting table........................................................................................................................... 754 Troubleshooting method for open circuit in wiring harness of pressure sensor system............................................................................ 756 Layout drawing of connector pins............................................................................................................................... 758 Connector list and layout...................................................................................................................................... 794 T- branch box and T- branch adapter table...................................................................................................................... 814 Table of fuse locations........................................................................................................................................ 817 Troubleshooting by failure code.................................................................................................................................... 826 Failure code [1500L0] Double Engagement of Transmission Clutches............................................................................................... 826 Failure code [1540N1] T/M overrun.............................................................................................................................. 827 Failure code [15B0NX] T/M Oil Filter Clogged................................................................................................................... 828 Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit....................................................................................................... 830 Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect.................................................................................................. 832 Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit....................................................................................................... 834 Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect.................................................................................................. 836 Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit....................................................................................................... 838 Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect.................................................................................................. 840 Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit....................................................................................................... 842 Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect.................................................................................................. 844 Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit....................................................................................................... 846 Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect.................................................................................................. 848 Failure code [2F00MA] Parking brake circuit failure............................................................................................................ 851 Failure code [2G42ZG] Accumulator Oil Press. F Low............................................................................................................. 854 Failure code [2G43ZG] Accumulator Oil Press. R Low............................................................................................................. 856 Failure code [44K0L4] Bucket cylinder position detector SW failure............................................................................................. 858 Failure code [7REAKA] ACC Signal Malfunction................................................................................................................... 859 Failure code [989P00] Direction protection warning............................................................................................................. 860 Failure code [989Q00] Work equipment protection................................................................................................................ 860 Failure code [989R00] Tire slip................................................................................................................................ 861 Failure code [989S00] Parking Brake Dragging................................................................................................................... 862 Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF).............................................................................................. 864 Failure code [989U00] Stationary steering (Brake: OFF, Load: ON)............................................................................................... 865 Failure code [989V00] Stationary steering (Brake: ON, Load: OFF)............................................................................................... 866 Failure code [989W00] Stationary steering (Brake: ON, Load: ON)................................................................................................ 867 Failure code [AA1ANX] Air Cleaner 1 Clogging................................................................................................................... 868 Failure code [AA1BNX] Air Cleaner 2 Clogging................................................................................................................... 870 Failure code [AA1CNX] Air Cleaner 3 Clogging................................................................................................................... 872 Failure code [AA1DNX] Air Cleaner 4 Clogging................................................................................................................... 874 Failure code [AB00L6] Discharge of alternator R terminal....................................................................................................... 876 Failure code [AB00MA] Discharge of alternator R terminal....................................................................................................... 878 Failure code [AB00MB] Discharge of alternator R terminal....................................................................................................... 880 Failure code [B@BCZK] Drop in Engine Coolant Level............................................................................................................. 882 Failure code [b@C5ZK] Low brake fluid level (before engine start).............................................................................................. 884 Failure code [B@C5ZK] Low brake fluid level (while engine is running).......................................................................................... 885 Failure code [B@C6NS] High brake oil temp...................................................................................................................... 886 Failure code [b@CENS] High torque converter oil temp........................................................................................................... 887 Failure code [B@CENS] Very high torque converter oil temp...................................................................................................... 888 Failure code [B@GAZK] Low battery 1 fluid level................................................................................................................ 890 Failure code [B@GBZK] Low battery 2 fluid level................................................................................................................ 892 Failure code [B@GCZK] Low battery 3 fluid level................................................................................................................ 894 Failure code [B@HANS] High hydraulic oil temp.................................................................................................................. 896 Failure code [B@HAZK] Low hydraulic oil level.................................................................................................................. 897 Failure code [D191KA] Neutral Output Relay Disconnection....................................................................................................... 898 Failure code [D191KB] Neutral Output Relay hot short........................................................................................................... 900 Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit).................................................................................... 902 Failure code [D19MKY] SW pump PNC solenoid Relay hot short..................................................................................................... 904 Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure................................................................................................... 906 Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure................................................................................................... 908 Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit).............................................................................. 910 Failure code [D5ZHKB] Starting Switch C signal circuit Hot short............................................................................................... 912 Failure code [D5ZHKZ] Starting Switch C signal circuit failure................................................................................................. 914 Failure code [D5ZHL6] Ignition C terminal Circuit Failure...................................................................................................... 916 Failure code [DAF5KP] Monitor Panel 5 V source sys Error....................................................................................................... 918 Failure code [DAFRKR] Communication Lost Monitor Panel Controller.............................................................................................. 920 Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source........................................................................................ 922 Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal..................................................................................................... 924 Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source.................................................................................... 926 Failure code [DAQRKR] Communication Lost T/M Controller........................................................................................................ 928 Failure code [DAQRMA] Defective Option Selection Data in Transmission.......................................................................................... 930 Failure code [DB2RKR] Communication Lost Engine Controller..................................................................................................... 932 Failure code [DB90KK] Drop in Work Controller Main Power Source................................................................................................ 934 Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal..................................................................................................... 936 Failure code [DB92KK] Solenoid Voltage Failure (Work controller)............................................................................................... 938 Failure code [DB95KX] 5 V source sys Error (Work controller)................................................................................................... 940 Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller.................................................................................... 942 Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller................................................................................ 944 Failure code [DB9RMC] Communication Lost (Work Controller)..................................................................................................... 946 Failure code [DBB0KK] VHMS source voltage Error................................................................................................................ 948 Failure code [DBB0KQ] VHMS Connector Mismatch.................................................................................................................. 950 Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V).............................................................................................. 952 Failure code [DBB5KP] VHMS 5 V source sys Error................................................................................................................ 954 Failure code [DBB6KP] VHMS 24 V source sys Error............................................................................................................... 956 Failure code [DBB7KP] VHMS 12 V source sys Error............................................................................................................... 958 Failure code [DBBQMC] Communication Lost (VHMS CAN0)........................................................................................................... 959 Failure code [DBBRKR] Communication Lost VHMS Controller....................................................................................................... 961 Failure code [DBBRMC] Communication Lost (VHMS CAN1)........................................................................................................... 962 Failure code [DD10KX] Verification Mode SW Failure............................................................................................................. 964 Failure code [DD1ALD] Remote positioner upper side set sw failure.............................................................................................. 966 Failure code [DD1BLD] Remote positioner lower side set sw failure.............................................................................................. 968 Failure code [DDA7L4] Throttle Lock Input signal Short Circuit................................................................................................. 970 Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit..................................................................................... 972 Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit..................................................................................... 974 Failure code [DDB6L4] Neutral Signal Malfunction............................................................................................................... 976 Failure code [DDD7KA] Speed control dial circuit (Low Voltage)................................................................................................. 978 Failure code [DDD7KB] Speed control dial circuit (High Voltage)................................................................................................ 980 Failure code [DDDBKA] Traction control dial circuit (Low Voltage).............................................................................................. 982 Failure code [DDDBKB] Traction control dial circuit (High Voltage)............................................................................................. 984 Failure code [DDE5MA] Emergency steering signal Failure........................................................................................................ 986 Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection.................................................................................................... 988 Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit.................................................................................................... 990 Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)............................................................................. 992 Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect......................................................................... 994 Failure code [DDT4LD] T/M Cut Off set switch signal short circuit.............................................................................................. 996 Failure code [DDW9LD] Kickdown Switch Short Circuit............................................................................................................ 998 Failure code [DGE5KX] Ambient air temp Sensor Failure..........................................................................................................1000 Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect....................................................................................1002 Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit.........................................................................1004 Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)..................................................................................1006 Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure...............................................................................................1008 Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection.............................................................................................1010 Failure code [DGR2KX] Brake oil temp. sensor circuit failure...................................................................................................1012 Failure code [DGT1KX] T/C oil temp. sensor circuit failure.....................................................................................................1014 Failure code [DH20KX] Torque converter pressure sensor circuit.................................................................................................1016 Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)..................................................................................1018 Failure code [DH21KB] Loader pump oil press sensor hot short...................................................................................................1020 Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)............................................................................................1022 Failure code [DHPCKX] Boom bottom press. sensor circuit failure................................................................................................1024 Failure code [DHPCKY] Boom bottom press. hot short.............................................................................................................1026 Failure code [DHPDKX] Boom head press. sensor circuit failure..................................................................................................1028 Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect............................................................................................1030 Failure code [DHT2L6] T/M oil filter sensor circuit failure....................................................................................................1032 Failure code [DHT3KX] Transmission main pressure sensor circuit................................................................................................1034 Failure code [DHT4KX] Main PPC oil pressure sensor circuit.....................................................................................................1036 Failure code [DHT5KX] Torque converter intake pressure sensor circuit40........................................................................................1038 Failure code [DHT8KX] Steering Oil Press. Sensor Failure.......................................................................................................1040 Failure code [DHTAKX] Transmission lubrication pressure sensor circuit40-......................................................................................1042 Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect.....................................................................................1044 Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit...................................................................................1046 Failure code [DHU2KA] F Brake Oil press Sensor Disconnect......................................................................................................1048 Failure code [DHU2KB] F Brake Oil press Sensor Hot short.......................................................................................................1050 Failure code [DHU2KX] F Brake Oil press Sensor Failure.........................................................................................................1052 Failure code [DHU3KA] R Brake Oil press Sensor Disconnect......................................................................................................1054 Troubleshooting by failure code 40-340 Failure code [DHU3KB] R Brake Oil press Sensor Hot short................................................................1056 Failure code [DHU3KX] R Brake Oil press Sensor Failure.........................................................................................................1057 Failure code [DJF1KA] Fuel level sensor circuit Disconnection..................................................................................................1059 Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit)...................................................................................1060 Failure code [DK30KY] Steering lever angle sensor circuit hot short............................................................................................1061 Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)...............................................................................1062 Failure code [DK59KY] Boom lever potentiometer (main) hot short................................................................................................1064 Failure code [DK59L8] Boom lever potentiometer (main & sub) failure............................................................................................1065 Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)................................................................................1068 Failure code [DK5AKY] Boom lever potentiometer (sub) hot short.................................................................................................1070 Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit).............................................................................1072 Failure code [DK5BKY] Bucket lever potentiometer (main) hot short..............................................................................................1074 Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure..........................................................................................1075 Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)..............................................................................1078 Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short...............................................................................................1079 Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit).............................................................................................1080 Failure code [DKA0KX] Boom angle sensor circuit failure........................................................................................................1082 Failure code [DKA0KY] Boom angle sensor circuit hot short......................................................................................................1084 Failure code [DKA0L0] Boom angle sensor failure................................................................................................................1086 Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)............................................................................................1088 Failure code [DKD0KY] Frame angle sensor circuit hot short.....................................................................................................1089 Failure code [DKD0KZ] Frame and steering angle sensor failure..................................................................................................1090 Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect.....................................................................................................1091 Failure code [DKH0KB] Angle sensor circuit (FR) Hot short......................................................................................................1092 Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect.....................................................................................................1094 Failure code [DKH1KB] Angle sensor circuit (LR) Hot short......................................................................................................1096 Failure code [DLE2KA] Engine Speed Sensor Disconnection........................................................................................................1098 Failure code [DLE2LC] Engine Speed Sensor Short Circuit........................................................................................................1100 Failure code [DLF6LC] Tire speed sensor circuit................................................................................................................1102 Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect.....................................................................................................1104 Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit..................................................................................................1106 Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit..............................................................................................1108 Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection..............................................................................................1110 Failure code [DT20KB] Transmission cut off indicator Output short circuit......................................................................................1112 Failure code [DT21KB] Speed Control indicator Output short circuit.............................................................................................1113 Failure code [DUM8KB] VHMS Operation lamp Short Circuit........................................................................................................1114 Failure code [DV00KY] Buzzer circuit hotshort (for usually)....................................................................................................1116 Failure code [DV01KY] Buzzer circuit hotshort (for special)....................................................................................................1118 Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection40...........................................................................................1120 Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit.............................................................................................1121 Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short.........................................................................................1122 Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection40...........................................................................................1123 Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit.............................................................................................1124 Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short.........................................................................................1125 Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection...........................................................................................1126 Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit40.........................................................................................1127 Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short.......................................................................................1128 Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection.................................................................................................1129 Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault.................................................................................................1130 Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short....................................................................................................1131 Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection................................................................................................1132 Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit.............................................................................................1133 Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short.................................................................................................1134 Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection...............................................................................................1135 Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault................................................................................................1136 Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short...................................................................................................1137 Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection..................................................................................................1138 Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit...............................................................................................1139 Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...................................................................................................1140 Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection.................................................................................................1141 Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault.................................................................................................1142 Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short....................................................................................................1143 Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection40...........................................................................................1144 Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault.................................................................................................1145 Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short....................................................................................................1146 Troubleshooting by failure code 40-431 Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection...........................................................1147 Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault....................................................................................................1148 Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short......................................................................................................1149 Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection..................................................................................................1150 Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit..................................................................................................1151 Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short......................................................................................................1152 Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection..............................................................................................1153 Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit..............................................................................................1154 Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short40........................................................................................1155 Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection.......................................................................................1156 Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit.......................................................................................1157 Failure code [DWM1KY] Work equipment neutral lock solenoid hot short40.........................................................................................1158 Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection........................................................................................1159 Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit........................................................................................1160 Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short............................................................................................1161 Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection........................................................................................1162 Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit........................................................................................1163 Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short............................................................................................1164 Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection.......................................................................................1165 Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit40.......................................................................................1166 Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short.............................................................................................1167 Troubleshooting by failure code 40-452 Failure code [DWNAKA] NC solenoid disconnection.........................................................................1168 Failure code [DWNAKB] NC solenoid short circuit................................................................................................................1169 Failure code [DWNAKY] NC solenoid hot short....................................................................................................................1170 Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)....................................................................................1171 Failure code [DXA1KY] Loader pump solenoid Relay hot short.....................................................................................................1173 Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)....................................................................................1175 Failure code [DXF0KA] AJSS EPC solenoid disconnection..........................................................................................................1177 Failure code [DXF0KB] AJSS EPC solenoid short circuit..........................................................................................................1179 Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection..................................................................................................1181 Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit..................................................................................................1183 Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short..............................................................................................1185 Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection..................................................................................................1187 Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit..................................................................................................1189 Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short..............................................................................................1191 Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection..................................................................................................1193 Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit..................................................................................................1195 Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short..............................................................................................1197 Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection....................................................................................................1199 Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit....................................................................................................1201 Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short................................................................................................1203 Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection....................................................................................................1205 Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit....................................................................................................1207 Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short................................................................................................1209 Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection................................................................................................1210 Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit................................................................................................1211 Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V........................................................................................1212 Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction..................................................................................................1213 Troubleshooting of electrical system (E-mode),.....................................................................................................................1215 E-1 Remote positioner "RAISE" or "LOWER" LED does not light up.................................................................................................1215 E-2 Open circuit or ground fault in check lamp system..........................................................................................................1216 E-3 Machine monitor does not operate...........................................................................................................................1217 E-4 Turn signal lamp does not light up.........................................................................................................................1218 E-5 Defective parking lamp.....................................................................................................................................1220 E-6 Defective front working lamp...............................................................................................................................1222 E-7 Defective rear working lamp................................................................................................................................1224 E-8 Headlamp does not light up.................................................................................................................................1226 E-9 Service meter does not work, or service meter works while engine is stopped................................................................................1228 E-10 Monitor panel controller does not sound buzzer............................................................................................................1230 E-11 Defective auto-greasing system............................................................................................................................1232 Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)....1234 Work equipment hydraulic system, general.......................................................................................................................1244 Work equipment oil pressure group..............................................................................................................................1246 Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)...............................................................1311 Checking steering related standard values......................................................................................................................1324 Steering oil pressure system, general..........................................................................................................................1325 Steering oil pressure group....................................................................................................................................1326 Brake oil pressure system, general.............................................................................................................................1366 Brake oil pressure group.......................................................................................................................................1367 Information contained in troubleshooting table (H mode)........................................................................................................1417 H-1 Torque converter oil temperature rises too high (overheats)................................................................................................1418 H-2 Turning or response of steering is poor....................................................................................................................1421 H-3 AJSS lever is hard to operate..............................................................................................................................1424 H-4 Steering shakes or jolts...................................................................................................................................1426 H-5 Wheel brake does not work at all or is weak................................................................................................................1428 H-6 Lift arm speed is low or lift arm rising force is insufficient.............................................................................................1430 H-7 Shock is large when lift arm stops.........................................................................................................................1433 H-8 Hydraulic oil temperature rises too high (overheating).....................................................................................................1434 50 Disassembly and assembly............................................................................................................................................1437 General information on disassembly and assembly....................................................................................................................1440 How to read Disassembly and Assembly...........................................................................................................................1440 Coating materials list.........................................................................................................................................1442 Special tool list..............................................................................................................................................1445 Sketches of special tools......................................................................................................................................1450 Flushing procedure.................................................................................................................................................1490 Flushing procedure for brake circuit...........................................................................................................................1490 Flushing procedure for work equipment and steering circuit.....................................................................................................1496 Air bleeding procedure.............................................................................................................................................1502 Bleeding air from brake circuit................................................................................................................................1502 Bleeding air from piston motor of brake and torque converter...................................................................................................1504 Bleeding air from piston pump..................................................................................................................................1506 Bleeding air from work equipment circuit and steering circuit..................................................................................................1507 Engine and cooling system..........................................................................................................................................1510 Removal and installation of radiator and hydraulic oil cooler assembly.........................................................................................1510 Removal and installation of engine assembly....................................................................................................................1517 Removal and installation of air-cooled torque converter and transmission,and brake oil cooler assembly.........................................................1524 Removal and installation of water-cooled torque converter and transmissionoil cooler assembly..................................................................1526 Removal and installation of damper assembly....................................................................................................................1527 Disassembly and assembly of damper.............................................................................................................................1529 Removal and installation of bumper and fuel tank assembly......................................................................................................1536 Removal and installation of hood assembly......................................................................................................................1538 Disassembly and assembly procedures for MESABI oil cooler......................................................................................................1540 Disassembly and assembly of MESABI oil cooler..................................................................................................................1543 Power train........................................................................................................................................................1551 Removal and installation of torque converter and transmission assembly.........................................................................................1551 Disconnection and connection of transmission assembly and torque converter assembly............................................................................1558 Disconnection and connection of torque converter assembly, PTO and transfer assembly...........................................................................1565 Disassembly and assembly of torque converter...................................................................................................................1569 Disassembly and assembly of modulation clutch..................................................................................................................1580 Disassembly and assembly of PTO and transfer...................................................................................................................1584 Disconnection and connection of transmission assembly, transfer, and parking brake assembly....................................................................1597 Disassembly and assembly of transmission assembly..............................................................................................................1604 Disassembly and assembly of transfer...........................................................................................................................1625 Disassembly and assembly of parking brake......................................................................................................................1632 Removal and installation of parking brake assembly (installed on the machine)..................................................................................1635 Removal and installation of transmission, brake cooling device and brake pump assembly.........................................................................1639 Removal and installation of steering pump, control pump and PPC pump assembly..................................................................................1640 Disassembly and assembly of drive shaft........................................................................................................................1641 Removal and installation of front axle assembly................................................................................................................1643 Removal and installation of front final drive assembly.........................................................................................................1645 Removal and installation of rear axle assembly.................................................................................................................1647 Removal and installation of rear final drive assembly..........................................................................................................1658 Removal and installation of differential assembly..............................................................................................................1661 Disassembly and assembly of differential.......................................................................................................................1663 Disassembly and assembly of final drive and brake..............................................................................................................1676 Removal and installation of center support assembly............................................................................................................1689 Disassembly and assembly of center support.....................................................................................................................1691 Steering system....................................................................................................................................................1695 Removal and installation of steering demand valve assembly.....................................................................................................1695 Removal and installation of steering cylinder assembly.........................................................................................................1696 Removal and installation of emergency diverter valve assembly..................................................................................................1700 Removal and installation of emergency steering pump assembly...................................................................................................1702 Brake system.......................................................................................................................................................1703 Removal and installation of brake accumulator charge valve assembly............................................................................................1703 Removal and installation of brake oil tank assembly............................................................................................................1704 Undercarriage and frame............................................................................................................................................1705 Procedure for disconnecting front frame and rear frame.........................................................................................................1705 Removal and installation of center hinge pin...................................................................................................................1706 Hydraulic system...................................................................................................................................................1722 Removal and installation of hydraulic tank, filter case assembly...............................................................................................1722 Removal and installation of No. 1 work equipment pump assembly.................................................................................................1724 Removal and installation of No. 2 work equipment pump assembly.................................................................................................1726 Removal and installation of switch pump assembly...............................................................................................................1727 Removal and installation of work equipment control valve assembly..............................................................................................1728 Work equipment.....................................................................................................................................................1742 Removal and installation of bucket cylinder assembly...........................................................................................................1742 Removal and installation of lift cylinder assembly.............................................................................................................1753 Disassembly and assembly of work equipment cylinder............................................................................................................1767 Removal and installation of work equipment assembly............................................................................................................1773 Procedure for running in bucket pin............................................................................................................................1829 Procedure for running in lift arm pin..........................................................................................................................1831 Cab................................................................................................................................................................1834 Removal and installation of bulkhead assembly..................................................................................................................1834 Removal and installation of operator's cab and floor assembly..................................................................................................1836 Removal and installation of operator's cab assembly............................................................................................................1840 Removal and installation of air conditioner unit assembly......................................................................................................1842 Disassembly and assembly of operator seat......................................................................................................................1844 Electrical system..................................................................................................................................................1877 Removal and installation of DT connector pin...................................................................................................................1877 Removal and installation of HD connector pin...................................................................................................................1879 Repairing HD connector pin harness.............................................................................................................................1880 Removal and installation of controller assembly................................................................................................................1881 60 Maintenance standard................................................................................................................................................1883 Engine and cooling system..........................................................................................................................................1885 Engine mount...................................................................................................................................................1885 Cooling system.................................................................................................................................................1886 Cooling fan motor..............................................................................................................................................1887 Damper.........................................................................................................................................................1889 Power train........................................................................................................................................................1890 Transmission mount.............................................................................................................................................1890 Torque converter...............................................................................................................................................1892 Main relief valve, torque converter relief valve...............................................................................................................1896 Torque converter regulator valve...............................................................................................................................1898 ECMV...........................................................................................................................................................1899 Transmission...................................................................................................................................................1900 Transmission control valve.....................................................................................................................................1902 Lubrication relief valve.......................................................................................................................................1905 Transfer.......................................................................................................................................................1906 Torque converter pump, transmission pump, brake cooling pump, brake pump.......................................................................................1908 Drive shaft....................................................................................................................................................1910 Center support.................................................................................................................................................1912 Differential...................................................................................................................................................1914 Final drive....................................................................................................................................................1918 Steering system....................................................................................................................................................1920 Steering pump..................................................................................................................................................1920 Switch pump....................................................................................................................................................1921 Steering demand valve..........................................................................................................................................1923 Diverter valve.................................................................................................................................................1925 Steering cylinder mount........................................................................................................................................1926 Steering cylinder..............................................................................................................................................1927 Emergency steering pump........................................................................................................................................1929 Brake system.......................................................................................................................................................1930 Brake valve....................................................................................................................................................1930 Slack adjuster.................................................................................................................................................1932 Brake..........................................................................................................................................................1933 Parking brake..................................................................................................................................................1934 Undercarriage and frame............................................................................................................................................1936 axle mount.....................................................................................................................................................1936 Center hinge pin...............................................................................................................................................1938 Hydraulic system...................................................................................................................................................1941 No.1 work equipment pump.......................................................................................................................................1941 No.2 work equipment pump.......................................................................................................................................1944 PPC relief valve...............................................................................................................................................1947 Pump control relief valve......................................................................................................................................1948 Work equipment control valve...................................................................................................................................1949 Work equipment.....................................................................................................................................................1951 Work equipment linkage.........................................................................................................................................1951 Bucket positioner, remote positioner...........................................................................................................................1956 Work equipment cylinder........................................................................................................................................1957 Electrical system..................................................................................................................................................1959 Work equipment control lever...................................................................................................................................1959 80 Appendix............................................................................................................................................................1961 Air conditioner....................................................................................................................................................1963 Precautions for refrigerant....................................................................................................................................1963 Configuration and function of refrigeration cycle..............................................................................................................1964 Outline of refrigeration cycle.................................................................................................................................1965 Control system.................................................................................................................................................1967 Air conditioner components.....................................................................................................................................1971 Compressor.....................................................................................................................................................1978 Electric fan and condenser.....................................................................................................................................1979 Receiver drier.................................................................................................................................................1981 Service tools..................................................................................................................................................1982 Troubleshooting procedures.....................................................................................................................................1989 Interview and confirmation of failure symptom..................................................................................................................1990 Basic checks...................................................................................................................................................1991 Troubleshooting................................................................................................................................................1992 Checking of refrigeration cycle................................................................................................................................1998 Troubleshooting for unusual noise..............................................................................................................................2006 Electrical system..............................................................................................................................................2007 Parts replacement..............................................................................................................................................2009 Periodic inspection and maintenance............................................................................................................................2012 Testing and adjusting compressor belt tension..................................................................................................................2016 90 Diagrams and drawings...............................................................................................................................................2017 Hydraulic circuit diagram..........................................................................................................................................2019 Circuit symbols used in hydraulic circuit diagrams.............................................................................................................2019 Transmission hydraulic circuit diagram.........................................................................................................................2022 Brake hydraulic circuit diagram................................................................................................................................2024 Work equipment hydraulic circuit diagram.......................................................................................................................2027 Electrical circuit diagram.........................................................................................................................................2029 Circuit symbols used in electrical circuit diagrams............................................................................................................2029 Electrical circuit diagram.....................................................................................................................................2033 Index..................................................................................................................................................................2046
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KOMATSU WA1200-6 WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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