Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN05475-26 – PDF DOWNLOAD

Description

Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN05475-26 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN05475-26 – PDF DOWNLOAD

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

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DESCRIPTION:

Komatsu WHEEL LOADER WA1200-6 Shop Manual SEN05475-26 – PDF DOWNLOAD

SERIAL NUMBERS 60001 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 SEN05475-26 – PDF DOWNLOAD

SERIAL NUMBERS 60001 and up

Cover 1
00 Index and foreword 3
Table of contents 4
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
Specification 63
Specification dimension drawing 63
Specifications 64
Weight table 67
Table of fuel, coolant and lubricants 69
10 Structure and function 71
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 85
Main relief valve and torque converter relief valve 94
Torque converter regulator valve 97
ECMV 99
Transmission 105
Transmission control valve 116
Transmission lubricating oil relief valve 126
Transfer 127
Torque converter oil cooler 129
Center support 130
Axle 131
Final drive 138
Steering system 139
Steering equipment layout drawing 139
AJSS 140
Steering pump 142
Switch pump 144
Steering demand valve 161
Rotary valve 171
EPC valve (for steering) 174
Diverter valve 175
Emergency steering relief valve 178
Steering lock valve 179
Brake system 180
Brake equipment layout drawing 180
Brake valve 181
Charge valve 187
Accumulator (for brake) 191
Slack adjuster 192
Brake 194
Parking brake 195
Parking brake solenoid valve 196
Emergency parking brake release valve 197
Check valve of parking brake circuit 198
Undercarriage and frame 201
Axle mount 201
Center hinge pin 203
Jack-up point 204
Hydraulic system 205
Hydraulic piping layout drawing 205
Work equipment control lever linkage 207
Hydraulic tank 208
Work equipment pump No1 211
Work equipment pump No2 224
EPC valve (for work equipment) 247
Neutral cutoff solenoid valve (NC valve) 249
Relief valve 251
Accumulator (for EPC valve) 252
Work equipment control valve 253
Work equipment 266
Work equipment linkage 266
Electrical system 268
Machine monitor system 268
Multi-function monitor 296
Work equipment and AJSS control system 349
Work equipment control lever 384
Transmission control system 387
Engine starting circuit 413
Engine stopping circuit 415
Electric parking brake control 419
Sensor 429
20 Standard value table 451
Standard value table 453
Standard value table for engine 453
Standard value table for chassis 454
30 Testing and adjusting 459
Precautions Before Work 462
Tool for testing, adjusting and troubleshooting 464
Tools for testing, adjusting, and troubleshooting 464
Safety precautions to follow before starting work 469
Engine and cooling system 473
Testing engine speed 473
Testing exhaust gas color 475
Testing blow-by pressure 476
Measuring engine oil pressure 477
Measuring exhaust gas temperature 478
Testing intake air pressure (boost pressure) 479
Testing radiator performance 480
Measuring wind speed across radiator and oil cooler 481
Testing and adjusting fan belt tension 482
Testing and adjusting air conditioner compressor belt tension 483
Power train 484
Adjusting speed sensor 484
Testing and adjusting torque converter and transmission oil pressure 486
Traction control function checking procedure 489
Testing torque converter oil cooler performance 490
Testing additional cooler fan speed 491
Flushing procedure for torque converter and transmission circuit 492
Retrieval of disabled machine due to transmission valve failure 493
How to measure play of center hinge bearing 496
Measuring wear of rear axle support 498
Steering system 499
Testing and adjusting steering oil pressure 499
Testing and adjusting emergency steering oil pressure 500
Bleeding air from steering circuit 502
Testing and adjusting steering stopper bolt 504
Adjusting steering follow-up linkage 505
Testing steering EPC valve 510
Testing and adjusting steering surge cut valve oil pressure 512
Testing and adjusting steering main relief valve oil pressure 514
Testing rotary valve output pressure 516
Brake system 518
Testing brake performance 518
Testing lowering of wheel brake oil pressure 519
Testing of slack adjuster 520
Mesuring wear of wheel brake disc 521
Testing and adjusting accumulator charge pressure 522
Testing brake accumulator oil pressure leakage 524
Testing emergency parking brake valve oil leakage amount 526
Testing brake valve oil leakage amount 529
Testing brake cooling oil pressure 536
Testing brake oil cooler performance 538
Testing parking brake performance 538
Testing wear of parking brake disc 539
Method of releasing parking brake manually 540
Testing parking brake oil pressure 541
Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 542
Hydraulic system 552
Testing and adjusting work equipment oil pressure by using multi monitor 552
Testing and adjusting work equipment oil pressure by using oil pressure gauge 554
Testing and adjusting work equipment PPC oil pressure 555
Measuring point of hydraulic pump oil pressure 557
Testing and adjusting PV control relief valve oil pressure 561
Testing and adjusting differential valve output oil pressure 563
Testing work pump ES valve output pressure 565
Testing and adjusting work pump CO (cut-off) valve oil pressure 567
Testing and adjusting work equipment pump TVC valve oil pressure 571
Operation test of work equipment valve by work equipment speed (speed of work equipment is low) 573
Testing hydraulic oil cooler performance 580
Bleeding air from hydraulic circuit 583
Releasing remaining pressure in hydraulic circuit 588
Work equipment 589
Checking center hinge pin lubrication 589
Adjustment method of auto grease injector delivery 591
Setting method of auto grease timer 592
Electrical system 594
Testing and adjusting bucket proximity switch 594
Adjusting lift arm potentiometer 595
Initial setting procedure for remote boom positioner (origin input method) 597
Checking proximity switch operation pilot lamp 598
Adjusting AJSS lever angle sensor and frame angle sensor 599
Testing and adjusting potentiometer mounting position 600
Procedure for testing diodes 603
Basic precautions for KOMTRAX Plus controller 604
Inspection and maintenance of KOMTRAX Plus controller 613
Initial setting procedure for KOMTRAX Plus controller 614
Precautions for replacing KOMTRAX Plus controller 631
Measurement procedure by downloading data in KOMTRAX Plus controller 639
Measurement procedure by multi monitor 643
Special functions of multi monitor 645
Pm Clinic 708
Outline of measurement procedure for Pm Clinic 708
Preparation for measurement for Pm Clinic 709
Pm clinic service 710
40 Troubleshooting 715
Precautions Before Work 722
General information on troubleshooting 724
Symptom and troubleshooting numbers 724
Sequence of events in troubleshooting 725
Check before troubleshooting 726
Classification and procedures of troubleshooting 737
Breakage of hydraulic cylinder 740
Failure codes table 743
Symptom and troubleshooting numbers 759
Information in troubleshooting table 760
Troubleshooting method for open circuit in wiring harness of pressure sensor system 762
Layout drawing of connector pins 764
Connector list and layout 800
T- branch box and T- branch adapter table 820
Table of fuse locations 823
Table of fuse locations (Pictorial SPEC) 826
Troubleshooting by failure code 832
Failure code [1500L0] Double Engagement of Transmission Clutches 832
Failure code [1540N1] T/M overrun 833
Failure code [15B0NX] T/M Oil Filter Clogged 834
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit 836
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect 838
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit 840
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect 842
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit 844
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect 846
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit 848
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect 850
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit 852
Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect 854
Failure code [2F00MA] Parking brake circuit failure 857
Failure code [2G42ZG] Accumulator Oil Press F Low 860
Failure code [2G43ZG] Accumulator Oil Press R Low 862
Failure code [44K0L4] Bucket cylinder position detector SW failure 864
Failure code [7REAKA] ACC Signal Malfunction 865
Failure code [989P00] Direction protection warning 866
Failure code [989Q00] Work equipment protection 866
Failure code [989R00] Tire slip 867
Failure code [989S00] Parking Brake Dragging 868
Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF) 870
Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) 871
Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) 872
Failure code [989W00] Stationary steering (Brake: ON, Load: ON) 873
Failure code [AA1ANX] Air Cleaner 1 Clogging 874
Failure code [AA1BNX] Air Cleaner 2 Clogging 876
Failure code [AA1CNX] Air Cleaner 3 Clogging 878
Failure code [AA1DNX] Air Cleaner 4 Clogging 880
Failure code [AB00L6] Discharge of alternator R terminal 882
Failure code [AB00MA] Discharge of alternator R terminal 884
Failure code [AB00MB] Discharge of alternator R terminal 886
Failure code [B@BCZK] Drop in Engine Coolant Level 888
Failure code [b@C5ZK] Low brake fluid level (before engine start) 890
Failure code [B@C5ZK] Low brake fluid level (while engine is running) 891
Failure code [B@C6NS] High brake oil temp 892
Failure code [b@CENS] High torque converter oil temp 893
Failure code [B@CENS] Very high torque converter oil temp 894
Failure code [B@GAZK] Low battery 1 fluid level 896
Failure code [B@GBZK] Low battery 2 fluid level 898
Failure code [B@GCZK] Low battery 3 fluid level 900
Failure code [B@HANS] High hydraulic oil temp 902
Failure code [B@HAZK] Low hydraulic oil level 903
Failure code [D191KA] Neutral Output Relay Disconnection 904
Failure code [D191KB] Neutral Output Relay hot short 906
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit) 908
Failure code [D19MKY] SW pump PNC solenoid Relay hot short 910
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure 912
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure 914
Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit) 916
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short 918
Failure code [D5ZHKZ] Starting Switch C signal circuit failure 920
Failure code [D5ZHL6] Ignition C terminal Circuit Failure 922
Failure code [DAF5KP] Monitor Panel 5 V source sys Error 924
Failure code [DAFRKR] Communication Lost Monitor Panel Controller 926
Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source 928
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal 930
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source 932
Failure code [DAQRKR] Communication Lost T/M Controller 934
Failure code [DAQRMA] Defective Option Selection Data in Transmission 936
Failure code [DB2RKR] Communication Lost Engine Controller 938
Failure code [DB90KK] Drop in Work Controller Main Power Source 940
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal 942
Failure code [DB92KK] Solenoid Voltage Failure (Work controller) 944
Failure code [DB95KX] 5 V source sys Error (Work controller) 946
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller 948
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller 950
Failure code [DB9RMC] Communication Lost (Work Controller) 952
Failure code [DBB0KK] VHMS source voltage Error 954
Failure code [DBB0KQ] VHMS Connector Mismatch 956
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V) 958
Failure code [DBB5KP] VHMS 5 V source sys Error 960
Failure code [DBB6KP] VHMS 24 V source sys Error 962
Failure code [DBB7KP] VHMS 12 V source sys Error 964
Failure code [DBBQMC] Communication Lost (VHMS CAN0) 965
Failure code [DBBRKR] Communication Lost VHMS Controller 967
Failure code [DBBRMC] Communication Lost (VHMS CAN1) 968
Failure code [DD10KX] Verification Mode SW Failure 970
Failure code [DD1ALD] Remote positioner upper side set sw failure 972
Failure code [DD1BLD] Remote positioner lower side set sw failure 974
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit 976
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit 978
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit 980
Failure code [DDB6L4] Neutral Signal Malfunction 982
Failure code [DDD7KA] Speed control dial circuit (Low Voltage) 984
Failure code [DDD7KB] Speed control dial circuit (High Voltage) 986
Failure code [DDDBKA] Traction control dial circuit (Low Voltage) 988
Failure code [DDDBKB] Traction control dial circuit (High Voltage) 990
Failure code [DDE5MA] Emergency steering signal Failure 992
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection 994
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit 996
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit) 998
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect1000
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit1002
Failure code [DDW9LD] Kickdown Switch Short Circuit1004
Failure code [DGE5KX] Ambient air temp Sensor Failure1006
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect1008
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit1010
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)1012
Failure code [DGH2KX] Hydraulic oil temp sensor circuit failure1014
Failure code [DGR2KA] Brake oil temp sensor circuit Disconnection1016
Failure code [DGR2KX] Brake oil temp sensor circuit failure1018
Failure code [DGT1KX] T/C oil temp sensor circuit failure1020
Failure code [DH20KX] Torque converter pressure sensor circuit1022
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)1024
Failure code [DH21KB] Loader pump oil press sensor hot short1026
Failure code [DHPCKA] Boom bottom press (Disconnect/Short Circuit)1028
Failure code [DHPCKX] Boom bottom press sensor circuit failure1030
Failure code [DHPCKY] Boom bottom press hot short1032
Failure code [DHPDKX] Boom head press sensor circuit failure1034
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect1036
Failure code [DHT2L6] T/M oil filter sensor circuit failure1038
Failure code [DHT3KX] Transmission main pressure sensor circuit1040
Failure code [DHT4KX] Main PPC oil pressure sensor circuit1042
Failure code [DHT5KX] Torque converter intake pressure sensor circuit1044
Failure code [DHT8KX] Steering Oil Press Sensor Failure1046
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit1048
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect1050
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit1052
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect1054
Failure code [DHU2KB] F Brake Oil press Sensor Hot short1056
Failure code [DHU2KX] F Brake Oil press Sensor Failure1058
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect1060
Failure code [DHU3KB] R Brake Oil press Sensor Hot short1062
Failure code [DHU3KX] R Brake Oil press Sensor Failure1063
Failure code [DJF1KA] Fuel level sensor circuit Disconnection1065
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit)1066
Failure code [DK30KY] Steering lever angle sensor circuit hot short1067
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)1068
Failure code [DK59KY] Boom lever potentiometer (main) hot short1070
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure1071
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)1074
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short1076
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)1078
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short1080
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure1081
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)1084
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short1085
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)1086
Failure code [DKA0KX] Boom angle sensor circuit failure1088
Failure code [DKA0KY] Boom angle sensor circuit hot short1090
Failure code [DKA0L0] Boom angle sensor failure1092
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)1094
Failure code [DKD0KY] Frame angle sensor circuit hot short1095
Failure code [DKD0KZ] Frame and steering angle sensor failure1096
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect1097
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short1098
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect1100
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short1102
Failure code [DLE2KA] Engine Speed Sensor Disconnection1104
Failure code [DLE2LC] Engine Speed Sensor Short Circuit1106
Failure code [DLF6LC] Tire speed sensor circuit1108
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect1110
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit1112
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit1114
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection1116
Failure code [DT20KB] Transmission cut off indicator Output short circuit1118
Failure code [DT21KB] Speed Control indicator Output short circuit1119
Failure code [DUM8KB] VHMS Operation lamp Short Circuit1120
Failure code [DV00KY] Buzzer circuit hotshort (for usually)1122
Failure code [DV01KY] Buzzer circuit hotshort (for special)1124
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection1126
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit1127
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short1128
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection1129
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit1130
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short1131
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection1132
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit1133
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short1134
Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection1135
Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault1136
Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short1137
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection1138
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit1139
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short1140
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection1141
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault1142
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short1143
Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection1144
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit1145
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short1146
Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection1147
Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault1148
Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short1149
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection1150
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault1151
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short1152
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection1153
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault1154
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short1155
Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection1156
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit1157
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short1158
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection1159
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit1160
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short1161
Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection1162
Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit1163
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short1164
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection1165
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit1166
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short1167
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection1168
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit1169
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short1170
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection1171
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit1172
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short1173
Failure code [DWNAKA] NC solenoid disconnection1174
Failure code [DWNAKB] NC solenoid short circuit1175
Failure code [DWNAKY] NC solenoid hot short1176
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)1177
Failure code [DXA1KY] Loader pump solenoid Relay hot short1179
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)1181
Failure code [DXF0KA] AJSS EPC solenoid disconnection1183
Failure code [DXF0KB] AJSS EPC solenoid short circuit1185
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection1187
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit1189
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short1191
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection1193
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit1195
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short1197
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection1199
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit1201
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short1203
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection1205
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit1207
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short1209
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection1211
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit1213
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short1215
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection1216
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit1217
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V1218
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction1219
Troubleshooting of electrical system (E-mode),1221
E-1 Remote positioner “RAISE” or “LOWER” LED does not light up1221
E-2 Open circuit or ground fault in check lamp system1222
E-3 Machine monitor does not operate1223
E-4 Turn signal lamp does not light up1224
E-5 Defective parking lamp1226
E-6 Defective front working lamp1228
E-7 Defective rear working lamp1230
E-8 Headlamp does not light up1232
E-9 Service meter does not work, or service meter works while engine is stopped1234
E-10 Monitor panel controller does not sound buzzer1236
E-11 Defective auto-greasing system1238
Troubleshooting of hydraulic and mechanical system (H-mode)1240
Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)1240
Work equipment hydraulic system, general1250
Work equipment oil pressure group1252
Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)1317
Checking steering related standard values1330
Steering oil pressure system, general1331
Steering oil pressure group1332
Brake oil pressure system, general1372
Brake oil pressure group1373
Information contained in troubleshooting table (H mode)1435
H-1 Torque converter oil temperature rises too high (overheats)1436
H-2 Turning or response of steering is poor1439
H-3 AJSS lever is hard to operate1442
H-4 Steering shakes or jolts1444
H-5 Wheel brake does not work at all or is weak1446
H-6 Lift arm speed is low or lift arm rising force is insufficient1448
H-7 Shock is large when lift arm stops1451
H-8 Hydraulic oil temperature rises too high (overheating)1452
50 Disassembly and assembly1455
CONTENTS1456
Precautions Before Work1458
General information on disassembly and assembly1460
How to read Disassembly and Assembly1460
Coating materials list1462
Special tool list1465
Sketches of special tools1479
Flushing procedure1517
Flushing procedure for brake circuit1517
Flushing procedure for work equipment and steering circuit1524
Air bleeding procedure1531
Bleeding air from brake circuit1531
Bleeding air from piston motor of brake and torque converter cooler1532
Bleeding air from piston pump1534
Bleeding air from work equipment circuit and steering circuit1535
Engine and cooling system1538
Removal and installation of radiator and hydraulic oil coolerassembly1538
Removal and installation of engine assembly1548
Removal and installation of air-cooled torque converter and transmission,and brake oil cooler assembly1556
Removal and installation of water-cooled torque converter andtransmission oil cooler assembly1559
Removal and installation of damper assembly1561
Disassembly and assembly of damper1564
Removal and installation of bumper and fuel tank assembly1573
Removal and installation of hood assembly1576
Disassembly and assembly procedures for MESABI oil cooler1578
Disassembly and assembly of MESABI oil cooler1581
Power train1591
Removal and installation of torque converter and transmissionassembly1591
Disconnection and connection of transmission assembly and torqueconverter assembly1603
Disconnection and connection of torque converter assembly, PTOand transfer assembly1611
Disassembly and assembly of torque converter1618
Disassembly and assembly of modulation clutch1629
Disassembly and assembly of PTO and transfer1633
Disconnection and connection of transmission assembly,transfer, and parking brake assembly1646
Disassembly and assembly of transmission assembly1656
Disassembly and assembly of transfer1679
Disassembly and assembly of parking brake1686
Removal and installation of parking brake assembly (installed onthe machine)1690
Removal and installation of transmission, brake cooling deviceand brake pump assembly1694
Removal and installation of steering pump, control pump and PPCpump assembly1697
Disassembly and assembly of drive shaft1699
Removal and installation of front axle assembly1701
Removal and installation of front final drive assembly1704
Removal and installation of rear axle assembly1708
Removal and installation of rear final drive assembly1722
Removal and installation of differential assembly1726
Disassembly and assembly of differential1729
Disassembly and assembly of final drive and brake1743
Removal and installation of center support assembly1758
Disassembly and assembly of center support1760
Steering system1765
Removal and installation of steering demand valve assembly1765
Removal and installation of steering cylinder assembly1767
Removal and installation of emergency diverter valve assembly1772
Removal and installation of emergency steering pump assembly1775
Brake system1777
Removal and installation of brake accumulator charge valveassembly1777
Removal and installation of brake oil tank assembly1779
Undercarriage and frame1781
Procedure for disconnecting front frame and rear frame1781
Removal and installation of center hinge pin1783
Hydraulic system1802
Removal and installation of hydraulic tank, filter case assembly1802
Removal and installation of No 1 work equipment pump assembly1805
Removal and installation of No 2 work equipment pump assembly1808
Removal and installation of switch pump assembly1810
Removal and installation of work equipment control valveassembly1812
Work equipment1829
Removal and installation of bucket cylinder assembly1829
Removal and installation of lift cylinder assembly1841
Disassembly and assembly of work equipment cylinder1856
Removal and installation of work equipment assembly1863
Procedure for running in bucket pin1929
Procedure for running in lift arm pin1932
Cab1935
Removal and installation of bulkhead assembly1935
Removal and installation of operator’s cab and floor assembly1937
Removal and installation of operator’s cab assembly1943
Removal and installation of air conditioner unit assembly1946
Disassembly and assembly of operator seat1948
Removal and installation of AJSS lever switch assembly1974
Electrical system1981
Removal and installation of DT connector pin1981
Removal and installation of HD connector pin1983
Repairing HD connector pin harness1985
Removal and installation of controller assembly1987
60 Maintenance standard1989
Engine and cooling system1991
Engine mount1991
Cooling system1992
Cooling fan motor1993
Damper1995
Power train1996
Transmission mount1996
Torque converter1998
Main relief valve, torque converter relief valve2002
Torque converter regulator valve2004
ECMV2005
Transmission2006
Transmission control valve2008
Lubrication relief valve2011
Transfer2012
Torque converter pump, transmission pump, brake cooling pump, brake pump2014
Drive shaft2016
Center support2018
Differential2020
Final drive2024
Steering system2026
Steering pump2026
Switch pump2027
Steering demand valve2029
Diverter valve2031
Steering cylinder mount2032
Steering cylinder2033
Emergency steering pump2035
Brake system2036
Brake valve2036
Slack adjuster2038
Brake2039
Parking brake2040
Undercarriage and frame2042
axle mount2042
Center hinge pin2044
Hydraulic system2049
No1 work equipment pump2049
No2 work equipment pump2052
PPC relief valve2055
Pump control relief valve2056
Work equipment control valve2057
Work equipment2059
Work equipment linkage2059
Bucket positioner, remote positioner2064
Work equipment cylinder2065
Electrical system2067
Work equipment control lever2067
80 Appendix2069
Precautions Before Work2071
Air conditioner2073
Precautions for refrigerant2073
Configuration and function of refrigeration cycle2074
Outline of refrigeration cycle2075
Control system2077
Air conditioner components2081
Compressor2088
Electric fan and condenser2089
Receiver drier2091
Service tools2092
Troubleshooting procedures2099
Interview and confirmation of failure symptom2100
Basic checks2101
Troubleshooting2102
Checking of refrigeration cycle2108
Troubleshooting for unusual noise2116
Electrical system2117
Parts replacement2119
Periodic inspection and maintenance2122
Testing and adjusting compressor belt tension2126
90 Diagrams and drawings2127
Hydraulic circuit diagram2129
Circuit symbols used in hydraulic circuit diagrams2129
Transmission hydraulic circuit diagram2132
Brake hydraulic circuit diagram2134
Work equipment hydraulic circuit diagram2139
Electrical circuit diagram2147
Circuit symbols used in electrical circuit diagrams2147
Electrical circuit diagram2151
Index2177
Colophon 2186

S.M 30/12/24