Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN06774-12 PDF

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Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN06774-12 – PDF DOWNLOAD

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Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN06774-12 – PDF DOWNLOAD

Language : English
Pages :2186
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN06774-12 – PDF DOWNLOAD

SERIAL NUMBERS 70001 and up

1. General precautions 

Inappropriate handling creates an extreme danger. Read and understand what is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is described in this manual before starting work.

TABLE OF CONTENTS:

Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN06774-12 – PDF DOWNLOAD

SERIAL NUMBERS 70001 and up

Cover 1
00 Index and foreword 3
Table of Contents 4
Foreword and general information 18
Safety notice 18
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling of hydraulic components 27
Method of disconnecting and connecting push-pull type coupler 29
Handling of electric equipment 32
How to read electric wire code 42
Precautions when performing work 45
Standard tightening torque table 48
List of abbreviation 52
Conversion table 56
01 Specification 61
Contents 62
Specification 63
Specification dimension drawing 63
Specifications 64
Weight table 67
Table of fuel, coolant and lubricants 69
10 Structure and function 71
Contents 72
Engine and cooling system 74
Damper 74
Cooling system 75
Cooling fan motor 76
Power train 81
Power train 81
Hydraulic piping drawing of torque converter and transmission 83
Torque converter 84
Main relief valve and torque converter relief valve 94
Torque converter regulator valve 97
ECMV 99
Transmission 106
Transmission control valve 116
Transmission lubricating oil relief valve 126
Transfer 127
Torque converter oil cooler 129
Center support 130
Axle 131
Final drive 137
Steering system 138
Steering equipment layout drawing 138
AJSS 139
Steering pump 140
Switch pump 142
Steering demand valve 160
Rotary valve 170
EPC valve (for steering) 173
Diverter valve 174
Emergency steering relief valve 177
Steering lock valve 178
Brake system 179
Brake equipment layout drawing 179
Brake valve 180
Charge valve 186
Accumulator (for brake) 190
Slack adjuster 191
Brake 193
Parking brake 194
Parking brake solenoid valve 195
Emergency parking brake release valve 196
Check valve of parking brake circuit 197
Undercarriage and frame 200
Axle mount 200
Center hinge pin 202
Jack-up point 203
Hydraulic system 204
Hydraulic piping layout drawing 204
Work equipment control lever linkage 206
Hydraulic tank 207
Work equipment pump No1 211
Work equipment pump No2 224
EPC valve (for work equipment) 248
Neutral cutoff solenoid valve (NC valve) 250
Relief valve 252
Accumulator (for EPC valve) 253
Work equipment control valve 254
Work equipment 268
Work equipment linkage 268
Electrical system 270
Machine monitor system 270
Multi-function monitor 298
Work equipment and AJSS control system 352
Work equipment control lever 388
Transmission control system 391
Engine starting circuit 417
Engine stopping circuit 419
Electric parking brake control 423
Sensor 433
20 Standard value table 455
Contents 456
Standard value table 457
Standard value table for engine 457
Standard value table for chassis 458
30 Testing and adjusting 463
Contents 464
Precautions Before Work 466
Tool for testing, adjusting and troubleshooting 468
Tools for testing, adjusting, and troubleshooting 468
Safety precautions to follow before starting work 473
Engine and cooling system 477
Testing engine speed 477
Testing exhaust gas color 479
Testing blow-by pressure 480
Measuring engine oil pressure 481
Measuring exhaust gas temperature 482
Testing intake air pressure (boost pressure) 483
Testing radiator performance 484
Measuring wind speed across radiator and oil cooler 485
Testing and adjusting fan belt tension 486
Testing and adjusting air conditioner compressor belt tension 487
Power train 488
Adjusting speed sensor 488
Testing and adjusting torque converter and transmission oil pressure 490
Traction control function checking procedure 493
Testing torque converter oil cooler performance 494
Testing additional cooler fan speed 495
Flushing procedure for torque converter and transmission circuit 496
Retrieval of disabled machine due to transmission valve failure 497
How to measure play of center hinge bearing 500
Measuring wear of rear axle support 502
Steering system 503
Testing and adjusting steering oil pressure 503
Testing and adjusting emergency steering oil pressure 504
Bleeding air from steering circuit 506
Testing and adjusting steering stopper bolt 508
Adjusting steering follow-up linkage 509
Testing steering EPC valve 514
Testing and adjusting steering surge cut valve oil pressure 516
Testing and adjusting steering main relief valve oil pressure 518
Testing rotary valve output pressure 520
Brake system 522
Testing brake performance 522
Testing lowering of wheel brake oil pressure 523
Testing of slack adjuster 524
Measuring wear of wheel brake disc 525
Testing and adjusting accumulator charge pressure 526
Testing brake accumulator oil pressure leakage 528
Testing emergency parking brake valve oil leakage amount 530
Testing brake valve oil leakage amount 533
Testing brake cooling oil pressure 538
Testing brake oil cooler performance 540
Testing parking brake performance 540
Testing wear of parking brake disc 541
Method of releasing parking brake manually 542
Testing parking brake oil pressure 543
Testing of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 544
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 591
Work equipment 593
Checking center hinge pin lubrication 593
Adjustment method of auto grease injector delivery 595
Setting method of auto grease timer 596
Electrical system 598
Testing and adjusting bucket proximity switch 598
Adjusting lift arm potentiometer 599
Initial setting procedure for remote boom positioner (origin input method) 601
Checking proximity switch operation pilot lamp 602
Adjusting AJSS lever angle sensor and frame angle sensor 603
Testing and adjusting potentiometer mounting position 604
Procedure for testing diodes 607
Basic precautions for KOMTRAX Plus controller 608
Inspection and maintenance of KOMTRAX Plus controller 617
Initial setting procedure for KOMTRAX Plus controller 618
Precautions for replacing KOMTRAX Plus controller 635
Measurement procedure by downloading data in KOMTRAX Plus controller 643
Measurement procedure by multi monitor 647
Special functions of multi monitor 649
Pm Clinic 712
Outline of measurement procedure for Pm Clinic 712
Preparation for measurement for Pm Clinic 713
Pm clinic service 714
40 Troubleshooting 719
Contents 720
Precautions Before Work 726
General information on troubleshooting 728
Symptom and troubleshooting numbers 728
Sequence of events in troubleshooting 729
Check before troubleshooting 730
Classification and procedures of troubleshooting 741
Breakage of hydraulic cylinder 744
Failure codes table 747
Symptom and troubleshooting numbers 763
Information in troubleshooting table 764
Troubleshooting method for open circuit in wiring harness of pressure sensor system 766
Layout drawing of connector pins 768
Connector list and layout 804
T- branch box and T- branch adapter table 824
Table of fuse locations 827
Troubleshooting by failure code 836
Failure code [1500L0] Double Engagement of Transmission Clutches 836
Failure code [1540N1] T/M overrun 837
Failure code [15B0NX] T/M Oil Filter Clogged 838
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit 840
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect 842
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit 844
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect 846
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit 848
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect 850
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit 852
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect 854
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit 856
Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect 858
Failure code [2F00MA] Parking brake circuit failure 861
Failure code [2G42ZG] Accumulator Oil Press F Low 864
Failure code [2G43ZG] Accumulator Oil Press R Low 866
Failure code [44K0L4] Bucket cylinder position detector SW failure 868
Failure code [7REAKA] ACC Signal Malfunction 869
Failure code [989P00] Direction protection warning 870
Failure code [989Q00] Work equipment protection 870
Failure code [989R00] Tire slip 871
Failure code [989S00] Parking Brake Dragging 872
Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF) 874
Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) 875
Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) 876
Failure code [989W00] Stationary steering (Brake: ON, Load: ON) 877
Failure code [AA1ANX] Air Cleaner 1 Clogging 878
Failure code [AA1BNX] Air Cleaner 2 Clogging 880
Failure code [AA1CNX] Air Cleaner 3 Clogging 882
Failure code [AA1DNX] Air Cleaner 4 Clogging 884
Failure code [AB00L6] Discharge of alternator R terminal 886
Failure code [AB00MA] Discharge of alternator R terminal 888
Failure code [AB00MB] Discharge of alternator R terminal 890
Failure code [B@BCZK] Drop in Engine Coolant Level 892
Failure code [b@C5ZK] Low brake fluid level (before engine start) 894
Failure code [B@C5ZK] Low brake fluid level (while engine is running) 895
Failure code [B@C6NS] High brake oil temp 896
Failure code [b@CENS] High torque converter oil temp 897
Failure code [B@CENS] Very high torque converter oil temp 898
Failure code [B@GAZK] Low battery 1 fluid level 900
Failure code [B@GBZK] Low battery 2 fluid level 902
Failure code [B@GCZK] Low battery 3 fluid level 904
Failure code [B@HANS] High hydraulic oil temp 906
Failure code [B@HAZK] Low hydraulic oil level 907
Failure code [D191KA] Neutral Output Relay Disconnection 908
Failure code [D191KB] Neutral Output Relay hot short 910
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit) 912
Failure code [D19MKY] SW pump PNC solenoid Relay hot short 914
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure 916
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure 918
Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit) 920
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short 922
Failure code [D5ZHKZ] Starting Switch C signal circuit failure 924
Failure code [D5ZHL6] Ignition C terminal Circuit Failure 926
Failure code [DAF5KP] Monitor Panel 5 V source sys Error 928
Failure code [DAFRKR] Communication Lost Monitor Panel Controller 930
Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source 932
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal 934
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source 936
Failure code [DAQRKR] Communication Lost T/M Controller 938
Failure code [DAQRMA] Defective Option Selection Data in Transmission 940
Failure code [DB2RKR] Communication Lost Engine Controller 942
Failure code [DB90KK] Drop in Work Controller Main Power Source 944
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal 946
Failure code [DB92KK] Solenoid Voltage Failure (Work controller) 948
Failure code [DB95KX] 5 V source sys Error (Work controller) 950
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller 952
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller 954
Failure code [DB9RMC] Communication Lost (Work Controller) 956
Failure code [DBB0KK] VHMS source voltage Error 958
Failure code [DBB0KQ] VHMS Connector Mismatch 960
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V) 962
Failure code [DBB5KP] VHMS 5 V source sys Error 964
Failure code [DBB6KP] VHMS 24 V source sys Error 966
Failure code [DBB7KP] VHMS 12 V source sys Error 968
Failure code [DBBQMC] Communication Lost (VHMS CAN0) 970
Failure code [DBBRKR] Communication Lost VHMS Controller 972
Failure code [DBBRMC] Communication Lost (VHMS CAN1) 974
Failure code [DD10KX] Verification Mode SW Failure 976
Failure code [DD1ALD] Remote positioner upper side set sw failure 978
Failure code [DD1BLD] Remote positioner lower side set sw failure 980
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit 982
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit 984
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit 986
Failure code [DDB6L4] Neutral Signal Malfunction 988
Failure code [DDD7KA] Speed control dial circuit (Low Voltage) 990
Failure code [DDD7KB] Speed control dial circuit (High Voltage) 992
Failure code [DDDBKA] Traction control dial circuit (Low Voltage) 994
Failure code [DDDBKB] Traction control dial circuit (High Voltage) 996
Failure code [DDE5MA] Emergency steering signal Failure 998
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection 1000
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit 1002
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit) 1004
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect1006
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit1008
Failure code [DDW9LD] Kickdown Switch Short Circuit1010
Failure code [DGE5KX] Ambient air temp Sensor Failure1012
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect1014
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit1016
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)1018
Failure code [DGH2KX] Hydraulic oil temp sensor circuit failure 1020
Failure code [DGR2KA] Brake oil temp sensor circuit Disconnection1022
Failure code [DGR2KX] Brake oil temp sensor circuit failure1024
Failure code [DGT1KX] T/C oil temp sensor circuit failure1026
Failure code [DH20KX] Torque converter pressure sensor circuit1028
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)1030
Failure code [DH21KB] Loader pump oil press sensor hot short1032
Failure code [DHPCKA] Boom bottom press (Disconnect/Short Circuit)1034
Failure code [DHPCKX] Boom bottom press sensor circuit failure1036
Failure code [DHPCKY] Boom bottom press hot short1038
Failure code [DHPDKX] Boom head press sensor circuit failure1040
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect1042
Failure code [DHT2L6] T/M oil filter sensor circuit failure1044
Failure code [DHT3KX] Transmission main pressure sensor circuit1046
Failure code [DHT4KX] Main PPC oil pressure sensor circuit1048
Failure code [DHT5KX] Torque converter intake pressure sensor circuit1050
Failure code [DHT8KX] Steering Oil Press Sensor Failure1052
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit1054
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect1056
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit1058
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect1060
Failure code [DHU2KB] F Brake Oil press Sensor Hot short1062
Failure code [DHU2KX] F Brake Oil press Sensor Failure 1064
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect 1066
Failure code [DHU3KB] R Brake Oil press Sensor Hot short1068
Failure code [DHU3KX] R Brake Oil press Sensor Failure1070
Failure code [DJF1KA] Fuel level sensor circuit Disconnection 1072
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit)1073
Failure code [DK30KY] Steering lever angle sensor circuit hot short1074
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)1076
Failure code [DK59KY] Boom lever potentiometer (main) hot short1078
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure1079
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit) 1082
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short1084
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)1086
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short1088
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure1089
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)1092
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short1093
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)1094
Failure code [DKA0KX] Boom angle sensor circuit failure1096
Failure code [DKA0KY] Boom angle sensor circuit hot short1098
Failure code [DKA0L0] Boom angle sensor failure1100
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)1102
Failure code [DKD0KY] Frame angle sensor circuit hot short1103
Failure code [DKD0KZ] Frame and steering angle sensor failure1104
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect1105
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short1106
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect1108
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short1110
Failure code [DLE2KA] Engine Speed Sensor Disconnection1112
Failure code [DLE2LC] Engine Speed Sensor Short Circuit1114
Failure code [DLF6LC] Tire speed sensor circuit1116
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect1118
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit1120
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit1122
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection1124
Failure code [DT20KB] Transmission cut off indicator Output short circuit1126
Failure code [DT21KB] Speed Control indicator Output short circuit 1127
Failure code [DUM8KB] VHMS Operation lamp Short Circuit 1128
Failure code [DV00KY] Buzzer circuit hotshort (for usually)1130
Failure code [DV01KY] Buzzer circuit hotshort (for special)1132
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection1134
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit1135
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short1136
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection 1137
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit 1138
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short 1139
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection 1140
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit1141
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short1142
Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection1143
Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault1144
Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short1145
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection1146
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit1147
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short1148
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection1149
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault1150
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short1151
Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection1152
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit1153
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short1154
Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection1155
Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault1156
Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short1157
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection1158
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault1159
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short1160
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection1161
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault1162
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short1163
Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection1164
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit1165
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short1166
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection1167
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit1168
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short1169
Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection1170
Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit1171
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short1172
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection1173
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit1174
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short1175
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection 1176
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit1177
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short1178
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection1179
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit 1180
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short 1181
Failure code [DWNAKA] NC solenoid disconnection1182
Failure code [DWNAKB] NC solenoid short circuit1183
Failure code [DWNAKY] NC solenoid hot short1184
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)1186
Failure code [DXA1KY] Loader pump solenoid Relay hot short1188
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)1190
Failure code [DXF0KA] AJSS EPC solenoid disconnection1192
Failure code [DXF0KB] AJSS EPC solenoid short circuit 1194
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection1196
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit 1198
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short1200
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection1202
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit1204
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short1206
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection1208
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit1210
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short1212
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection1214
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit1216
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short1218
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection1220
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit1222
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short1224
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection1225
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit1226
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V1227
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction1228
Troubleshooting of electrical system (E-mode)1230
E-1 Remote positioner “RAISE” or “LOWER” LED does not light up1230
E-2 Open circuit or ground fault in check lamp system1231
E-3 Machine monitor does not operate1232
E-4 Turn signal lamp does not light up1234
E-5 Defective parking lamp1236
E-6 Defective front working lamp1238
E-7 Defective rear working lamp1240
E-8 Headlamp does not light up1242
E-9 Service meter does not work, or service meter works while engine is stopped1244
E-10 Monitor panel controller does not sound buzzer1246
E-11 Defective auto-greasing system1248
Troubleshooting of hydraulic and mechanical system (H-mode)1250
Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)1250
Work equipment hydraulic system, general1260
Work equipment oil pressure group1262
Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)1327
Checking steering related standard values1340
Steering oil pressure system, general1341
Steering oil pressure group1342
Brake oil pressure system, general1382
Brake oil pressure group1384
Information contained in troubleshooting table (H mode)1438
H-1 Torque converter oil temperature rises too high (overheats)1439
H-2 Turning or response of steering is poor1442
H-3 AJSS lever is hard to operate1445
H-4 Steering shakes or jolts1447
H-5 Wheel brake does not work at all or is weak1449
H-6 Lift arm speed is low or lift arm rising force is insufficient1451
H-7 Shock is large when lift arm stops1454
H-8 Hydraulic oil temperature rises too high (overheating)1455
50 Disassembly and assembly1457
CONTENTS1458
Precautions Before Work1460
General information on disassembly and assembly1462
How to read Disassembly and Assembly1462
Coating materials list1464
Special tool list1467
Sketches of special tools1481
Flushing procedure1519
Flushing procedure for brake circuit1519
Flushing procedure for work equipment and steering circuit1532
Air bleeding procedure1539
Bleeding air from brake circuit1539
Bleeding air from piston motor of brake and torque converter cooler1540
Bleeding air from piston pump1542
Bleeding air from work equipment circuit and steering circuit1543
Engine and cooling system1546
Removal and installation of radiator and hydraulic oil coolerassembly1546
Removal and installation of engine assembly1556
Removal and installation of air-cooled torque converter and transmission,and brake oil cooler assembly1564
Removal and installation of water-cooled torque converter andtransmission oil cooler assembly1567
Removal and installation of damper assembly1569
Disassembly and assembly of damper1572
Removal and installation of bumper and fuel tank assembly1581
Removal and installation of hood assembly1584
Disassembly and assembly procedures for MESABI oil cooler1586
Disassembly and assembly of MESABI oil cooler1589
Power train1599
Removal and installation of torque converter and transmissionassembly1599
Disconnection and connection of transmission assembly and torqueconverter assembly1611
Disconnection and connection of torque converter assembly, PTOand transfer assembly1619
Disassembly and assembly of torque converter1626
Disassembly and assembly of modulation clutch1637
Disassembly and assembly of PTO and transfer1641
Disconnection and connection of transmission assembly,transfer, and parking brake assembly1654
Disassembly and assembly of transmission assembly1664
Disassembly and assembly of transfer1687
Disassembly and assembly of parking brake1694
Removal and installation of parking brake assembly (installed onthe machine)1698
Removal and installation of transmission, brake cooling deviceand brake pump assembly1702
Removal and installation of steering pump, control pump and PPCpump assembly1704
Disassembly and assembly of drive shaft1706
Removal and installation of front axle assembly1708
Removal and installation of front final drive assembly1711
Removal and installation of rear axle assembly1715
Removal and installation of rear final drive assembly1729
Removal and installation of differential assembly1733
Disassembly and assembly of differential1736
Disassembly and assembly of final drive and brake1750
Removal and installation of center support assembly1765
Disassembly and assembly of center support1767
Steering system1772
Removal and installation of steering demand valve assembly1772
Removal and installation of steering cylinder assembly1774
Removal and installation of emergency diverter valve assembly1779
Removal and installation of emergency steering pump assembly1782
Brake system1784
Removal and installation of brake accumulator charge valveassembly1784
Removal and installation of brake oil tank assembly1785
Undercarriage and frame1787
Procedure for disconnecting front frame and rear frame1787
Removal and installation of center hinge pin1789
Hydraulic system1808
Removal and installation of hydraulic tank, filter case assembly1808
Removal and installation of No 1 work equipment pump assembly1811
Removal and installation of No 2 work equipment pump assembly1814
Removal and installation of switch pump assembly1816
Removal and installation of work equipment control valveassembly1818
Work equipment1835
Removal and installation of bucket cylinder assembly1835
Removal and installation of lift cylinder assembly1847
Disassembly and assembly of work equipment cylinder1862
Removal and installation of work equipment assembly1869
Procedure for running in bucket pin1935
Procedure for running in lift arm pin1938
Cab1941
Removal and installation of bulkhead assembly1941
Removal and installation of operator’s cab and floor assembly1943
Removal and installation of operator’s cab assembly1949
Removal and installation of air conditioner unit assembly1952
Disassembly and assembly of operator seat1954
Removal and installation of AJSS lever switch assembly1980
Electrical system1987
Removal and installation of DT connector pin1987
Removal and installation of HD connector pin1989
Repairing HD connector pin harness1991
Removal and installation of controller assembly1993
60 Maintenance standard1995
Contents1996
Engine and cooling system1997
Engine mount1997
Cooling system1998
Cooling fan motor1999
Damper2001
Power train2002
Transmission mount2002
Torque converter2004
Main relief valve, torque converter relief valve2008
Torque converter regulator valve2010
ECMV2011
Transmission2012
Transmission control valve2014
Lubrication relief valve2017
Transfer2018
Drive shaft2020
Center support 2022
Differential2024
Final drive2028
Steering system2030
Steering pump2030
Switch pump2031
Steering demand valve2033
Diverter valve2035
Steering cylinder mount 2036
Steering cylinder2037
Emergency steering pump2039
Brake system2040
Brake valve2040
Slack adjuster2042
Brake2043
Parking brake2044
Undercarriage and frame2046
Axle mount2046
Center hinge pin2048
Hydraulic system2053
No1 work equipment pump2053
No2 work equipment pump2056
PPC relief valve2059
Pump control relief valve2060
Work equipment control valve2061
Work equipment2063
Work equipment linkage2063
Bucket positioner, remote positioner2068
Work equipment cylinder2069
Electrical system2071
Work equipment control lever2071
80 Appendix2073
Contents2074
Precautions Before Work2075
Air conditioner2077
Precautions for refrigerant2077
Configuration and function of refrigeration cycle2078
Outline of refrigeration cycle2079
Control system2081
Air conditioner components2086
Compressor2093
Electric fan and condenser2094
Receiver drier2096
Service tools 2097
Troubleshooting procedures2104
Interview and confirmation of failure symptom2105
Basic checks2106
Troubleshooting2107
Checking of refrigeration cycle2113
Troubleshooting for unusual noise2121
Electrical system2122
Parts replacement2124
Periodic inspection and maintenance2127
Testing and adjusting compressor belt tension2131
90 Diagrams and drawings2133
Contents2134
Hydraulic circuit diagram2135
Circuit symbols used in hydraulic circuit diagrams2135
Transmission hydraulic circuit diagram2138
Brake hydraulic circuit diagram2140
Work equipment hydraulic circuit diagram2143
Electrical circuit diagram2147
Circuit symbols used in electrical circuit diagrams2147
Electrical circuit diagram2151
INDEX2177
Colophon2186

S.M 30/12/24