Komatsu Wheel Loaders WA1200 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA1200, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loaders WA1200 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 11,589 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
Cover...1
Notice of revision ...3
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...150
Steering system...151
Steering equipment layout drawing...151
AJSS...152
Steering pump...154
Switch pump...156
Steering demand valve...173
Rotary valve...183
EPC valve (for steering)...186
Diverter valve...187
Emergency steering relief valve...190
Steering lock valve...191
Brake system...192
Brake equipment layout drawing...192
Brake valve...193
Charge valve...199
Accumulator (for brake)...203
Slack adjuster...204
Brake...206
Parking brake...207
Parking brake solenoid valve...208
Emergency parking brake release valve...209
Check valve of parking brake circuit...210
Undercarriage and frame...213
Axle mount...213
Center hinge pin...215
Jack-up point...216
Hydraulic system...217
Hydraulic piping layout drawing...217
Work equipment control lever linkage...219
Hydraulic tank...220
Work equipment pump No.1...223
Work equipment pump No.2...236
EPC valve (for work equipment)...259
Neutral cutoff solenoid valve (NC valve)...261
Relief valve...263
Accumulator (for EPC valve)...264
Work equipment control valve...265
Work equipment...278
Work equipment linkage...278
Electrical system...280
Machine monitor system...280
Multi-function monitor...308
Work equipment and AJSS control system...361
Work equipment control lever...396
Transmission control system...399
Engine starting circuit...425
Engine stopping circuit...427
Electric parking brake control...431
Sensor...441
20 Standard value table...463
Standard value table...465
Standard value table for engine...465
Standard value table for chassis...466
30 Testing and adjusting...471
Tool for testing, adjusting and troubleshooting...474
Tools for testing, adjusting, and troubleshooting...474
Safety precautions to follow before starting work...479
Engine and cooling system...483
Testing engine speed...483
Testing exhaust gas color...485
Testing blow-by pressure...486
Measuring engine oil pressure...487
Measuring exhaust gas temperature...488
Testing intake air pressure (boost pressure)...489
Testing radiator performance...490
Measuring wind speed across radiator and oil cooler...491
Testing and adjusting fan belt tension...492
Testing and adjusting air conditioner compressor belt tension...493
Power train...494
Adjusting speed sensor...494
Testing and adjusting torque converter and transmission oil pressure...496
Traction control function checking procedure...499
Testing torque converter oil cooler performance...500
Testing additional cooler fan speed...501
Flushing procedure for torque converter and transmission circuit...502
Retrieval of disabled machine due to transmission valve failure...503
How to measure play of center hinge bearing...506
Measuring wear of rear axle support...508
Steering system...509
Testing and adjusting steering oil pressure...509
Testing and adjusting emergency steering oil pressure...510
Bleeding air from steering circuit...512
Testing and adjusting steering stopper bolt...514
Adjusting steering follow-up linkage...515
Testing steering EPC valve...520
Testing and adjusting steering surge cut valve oil pressure...522
Testing and adjusting steering main relief valve oil pressure...524
Testing rotary valve output pressure...526
Brake system...528
Testing brake performance...528
Testing lowering of wheel brake oil pressure...529
Testing of slack adjuster...530
Mesuring wear of wheel brake disc...531
Testing and adjusting accumulator charge pressure...532
Testing brake accumulator oil pressure leakage...534
Testing emergency parking brake valve oil leakage amount...536
Testing brake valve oil leakage amount...539
Testing brake cooling oil pressure...544
Testing brake oil cooler performance...546
Testing parking brake performance...546
Testing wear of parking brake disc...547
Method of releasing parking brake manually...548
Testing parking brake oil pressure...549
Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas...550
Hydraulic system...558
Testing and adjusting work equipment oil pressure by using multi monitor...558
Testing and adjusting work equipment oil pressure by using oil pressure gauge...560
Testing and adjusting work equipment PPC oil pressure...561
Measuring point of hydraulic pump oil pressure...563
Testing and adjusting PV control relief valve oil pressure...567
Testing and adjusting differential valve output oil pressure...569
Testing work pump ES valve output pressure...571
Testing and adjusting work pump CO (cut-off) valve oil pressure...573
Testing and adjusting work equipment pump TVC valve oil pressure...577
Operation test of work equipment valve by work equipment speed (speed of work equipment is low)...579
Testing hydraulic oil cooler performance...586
Bleeding air from hydraulic circuit...589
Releasing remaining pressure in hydraulic circuit...594
Work equipment...595
Checking center hinge pin lubrication...595
Adjustment method of auto grease injector delivery...597
Setting method of auto grease timer...598
Electrical system...600
Testing and adjusting bucket proximity switch...600
Adjusting lift arm potentiometer...601
Adjusting lift arm levelness detecting switch...602
Initial setting procedure for remote boom positioner (origin input method)...603
Checking proximity switch operation pilot lamp...604
Adjusting AJSS lever angle sensor and frame angle sensor...605
Testing and adjusting potentiometer mounting position...606
Procedure for testing diodes...609
Basic precautions for KOMTRAX Plus controller...610
Inspection and maintenance of KOMTRAX Plus controller...619
Initial setting procedure for KOMTRAX Plus controller...620
Precautions for replacing KOMTRAX Plus controller...637
Measurement procedure by downloading data in KOMTRAX Plus controller...645
Measurement procedure by multi monitor...649
Special functions of multi monitor...651
Pm Clinic...714
Outline of measurement procedure for Pm Clinic...714
Preparation for measurement for Pm Clinic...715
Pm clinic service...716
40 Troubleshooting...721
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
Table of fuse locations (Pictorial SPEC.)...830
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)...969
Failure code [DBBRKR] Communication Lost VHMS Controller...971
Failure code [DBBRMC] Communication Lost (VHMS CAN1)...972
Failure code [DD10KX] Verification Mode SW Failure...974
Failure code [DD1ALD] Remote positioner upper side set sw failure...976
Failure code [DD1BLD] Remote positioner lower side set sw failure...978
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit...980
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit...982
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit...984
Failure code [DDB6L4] Neutral Signal Malfunction...986
Failure code [DDD7KA] Speed control dial circuit (Low Voltage)...988
Failure code [DDD7KB] Speed control dial circuit (High Voltage)...990
Failure code [DDDBKA] Traction control dial circuit (Low Voltage)...992
Failure code [DDDBKB] Traction control dial circuit (High Voltage)...994
Failure code [DDE5MA] Emergency steering signal Failure...996
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection...998
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit...1000
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)...1002
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect...1004
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit...1006
Failure code [DDW9LD] Kickdown Switch Short Circuit...1008
Failure code [DGE5KX] Ambient air temp Sensor Failure...1010
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect...1012
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit...1014
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)...1016
Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure...1018
Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection...1020
Failure code [DGR2KX] Brake oil temp. sensor circuit failure...1022
Failure code [DGT1KX] T/C oil temp. sensor circuit failure...1024
Failure code [DH20KX] Torque converter pressure sensor circuit...1026
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)...1028
Failure code [DH21KB] Loader pump oil press sensor hot short...1030
Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)...1032
Failure code [DHPCKX] Boom bottom press. sensor circuit failure...1034
Failure code [DHPCKY] Boom bottom press. hot short...1036
Failure code [DHPDKX] Boom head press. sensor circuit failure...1038
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect...1040
Failure code [DHT2L6] T/M oil filter sensor circuit failure...1042
Failure code [DHT3KX] Transmission main pressure sensor circuit...1044
Failure code [DHT4KX] Main PPC oil pressure sensor circuit...1046
Failure code [DHT5KX] Torque converter intake pressure sensor circuit...1048
Failure code [DHT8KX] Steering Oil Press. Sensor Failure...1050
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit...1052
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect...1054
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit...1056
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect...1058
Failure code [DHU2KB] F Brake Oil press Sensor Hot short...1060
Failure code [DHU2KX] F Brake Oil press Sensor Failure...1062
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect...1064
Failure code [DHU3KB] R Brake Oil press Sensor Hot short...1066
Failure code [DHU3KX] R Brake Oil press Sensor Failure...1067
Failure code [DJF1KA] Fuel level sensor circuit Disconnection...1069
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit)...1070
Failure code [DK30KY] Steering lever angle sensor circuit hot short...1071
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)...1072
Failure code [DK59KY] Boom lever potentiometer (main) hot short...1074
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure...1075
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)...1078
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short...1080
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)...1082
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short...1084
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure...1085
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)...1088
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short...1089
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)...1090
Failure code [DKA0KX] Boom angle sensor circuit failure...1092
Failure code [DKA0KY] Boom angle sensor circuit hot short...1094
Failure code [DKA0L0] Boom angle sensor failure...1096
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)...1098
Failure code [DKD0KY] Frame angle sensor circuit hot short...1099
Failure code [DKD0KZ] Frame and steering angle sensor failure...1100
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect...1101
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short...1102
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect...1104
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short...1106
Failure code [DLE2KA] Engine Speed Sensor Disconnection...1108
Failure code [DLE2LC] Engine Speed Sensor Short Circuit...1110
Failure code [DLF6LC] Tire speed sensor circuit...1112
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect...1114
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit...1116
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit...1118
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection...1120
Failure code [DT20KB] Transmission cut off indicator Output short circuit...1122
Failure code [DT21KB] Speed Control indicator Output short circuit...1123
Failure code [DUM8KB] VHMS Operation lamp Short Circuit...1124
Failure code [DV00KY] Buzzer circuit hotshort (for usually)...1126
Failure code [DV01KY] Buzzer circuit hotshort (for special)...1128
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection...1130
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit...1131
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short...1132
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection...1133
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit...1134
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short...1135
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection...1136
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit...1137
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short...1138
Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection...1139
Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault...1140
Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short...1141
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection...1142
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit...1143
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short...1144
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection...1145
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault...1146
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short...1147
Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection...1148
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit...1149
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...1150
Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection...1151
Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault...1152
Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short...1153
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection...1154
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault...1155
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short...1156
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection...1157
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault...1158
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short...1159
Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection...1160
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit...1161
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short...1162
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection...1163
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit...1164
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short...1165
Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection...1166
Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit...1167
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short...1168
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection...1169
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit...1170
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short...1171
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection...1172
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit...1173
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short...1174
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection...1175
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit...1176
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short...1177
Failure code [DWNAKA] NC solenoid disconnection...1178
Failure code [DWNAKB] NC solenoid short circuit...1179
Failure code [DWNAKY] NC solenoid hot short...1180
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)...1181
Failure code [DXA1KY] Loader pump solenoid Relay hot short...1183
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)...1185
Failure code [DXF0KA] AJSS EPC solenoid disconnection...1187
Failure code [DXF0KB] AJSS EPC solenoid short circuit...1189
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection...1191
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit...1193
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short...1195
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection...1197
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit...1199
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short...1201
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection...1203
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit...1205
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short...1207
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection...1209
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit...1211
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short...1213
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection...1215
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit...1217
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short...1219
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection...1220
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit...1221
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V...1222
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction...1223
Troubleshooting of electrical system (E-mode),...1225
E-1 Remote positioner "RAISE" or "LOWER" LED does not light up...1225
E-2 Open circuit or ground fault in check lamp system...1226
E-3 Machine monitor does not operate...1227
E-4 Turn signal lamp does not light up...1228
E-5 Defective parking lamp...1230
E-6 Defective front working lamp...1232
E-7 Defective rear working lamp...1234
E-8 Headlamp does not light up...1236
E-9 Service meter does not work, or service meter works while engine is stopped...1238
E-10 Monitor panel controller does not sound buzzer...1240
E-11 Defective auto-greasing system...1242
Troubleshooting of hydraulic and mechanical system (H-mode)...1244
Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)...1244
Work equipment hydraulic system, general...1254
Work equipment oil pressure group...1256
Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)...1321
Checking steering related standard values...1334
Steering oil pressure system, general...1335
Steering oil pressure group...1336
Brake oil pressure system, general...1376
Brake oil pressure group...1377
Information contained in troubleshooting table (H mode)...1427
H-1 Torque converter oil temperature rises too high (overheats)...1428
H-2 Turning or response of steering is poor...1431
H-3 AJSS lever is hard to operate...1434
H-4 Steering shakes or jolts...1436
H-5 Wheel brake does not work at all or is weak...1438
H-6 Lift arm speed is low or lift arm rising force is insufficient...1440
H-7 Shock is large when lift arm stops...1443
H-8 Hydraulic oil temperature rises too high (overheating)...1444
50 Disassembly and assembly...1447
General information on disassembly and assembly...1450
How to read Disassembly and Assembly...1450
Coating materials list...1452
Special tool list...1455
Sketches of special tools...1460
Flushing procedure...1500
Flushing procedure for brake circuit...1500
Flushing procedure for work equipment and steering circuit...1506
Air bleeding procedure...1512
Bleeding air from brake circuit...1512
Bleeding air from piston motor of brake and torque converter...1514
Bleeding air from piston pump...1516
Bleeding air from work equipment circuit and steering circuit...1517
Engine and cooling system...1520
Removal and installation of radiator and hydraulic oil cooler assembly...1520
Removal and installation of engine assembly...1527
Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly...1534
Removal and installation of water-cooled torque converter and transmission oil cooler assembly...1536
Removal and installation of damper assembly...1537
Disassembly and assembly of damper...1539
Removal and installation of bumper and fuel tank assembly...1546
Removal and installation of hood assembly...1548
Disassembly and assembly procedures for MESABI oil cooler...1550
Disassembly and assembly of MESABI oil cooler...1553
Power train...1561
Removal and installation of torque converter and transmission assembly...1561
Disconnection and connection of transmission assembly and torque converter assembly...1568
Disconnection and connection of torque converter assembly, PTO and transfer assembly...1575
Disassembly and assembly of torque converter...1579
Disassembly and assembly of modulation clutch...1590
Disassembly and assembly of PTO and transfer...1594
Disconnection and connection of transmission assembly, transfer, and parking brake assembly...1607
Disassembly and assembly of transmission assembly...1614
Disassembly and assembly of transfer...1635
Disassembly and assembly of parking brake...1642
Removal and installation of parking brake assembly (installed on the machine)...1645
Removal and installation of transmission, brake cooling device and brake pump assembly...1649
Removal and installation of steering pump, control pump and PPC pump assembly...1650
Disassembly and assembly of drive shaft...1651
Removal and installation of front axle assembly...1653
Removal and installation of front final drive assembly...1655
Removal and installation of rear axle assembly...1657
Removal and installation of rear final drive assembly...1668
Removal and installation of differential assembly...1671
Disassembly and assembly of differential...1673
Disassembly and assembly of final drive and brake...1686
Removal and installation of center support assembly...1699
Disassembly and assembly of center support...1701
Steering system...1705
Removal and installation of steering demand valve assembly...1705
Removal and installation of steering cylinder assembly...1706
Removal and installation of emergency diverter valve assembly...1710
Removal and installation of emergency steering pump assembly...1712
Brake system...1713
Removal and installation of brake accumulator charge valve assembly...1713
Removal and installation of brake oil tank assembly...1714
Undercarriage and frame...1715
Procedure for disconnecting front frame and rear frame...1715
Removal and installation of center hinge pin...1716
Hydraulic system...1732
Removal and installation of hydraulic tank, filter case assembly...1732
Removal and installation of No. 1 work equipment pump assembly...1734
Removal and installation of No. 2 work equipment pump assembly...1736
Removal and installation of switch pump assembly...1737
Removal and installation of work equipment control valve assembly...1738
Work equipment...1752
Removal and installation of bucket cylinder assembly...1752
Removal and installation of lift cylinder assembly...1763
Disassembly and assembly of work equipment cylinder...1777
Removal and installation of work equipment assembly...1783
Procedure for running in bucket pin...1841
Procedure for running in lift arm pin...1843
Removal and installation ofAJSS lever switch assembly...1889
Cab...1846
Removal and installation of bulkhead assembly...1846
Removal and installation of operator's cab and floor assembly...1848
Removal and installation of operator's cab assembly...1852
Removal and installation of air conditioner unit assembly...1854
Disassembly and assembly of operator seat...1856
Electrical system...1895
Removal and installation of DT connector pin...1895
Removal and installation of HD connector pin...1897
Repairing HD connector pin harness...1898
Removal and installation of controller assembly...1899
60 Maintenance standard...1901
Engine and cooling system...1903
Engine mount...1903
Cooling system...1904
Cooling fan motor...1905
Damper...1907
Power train...1908
Transmission mount...1908
Torque converter...1910
Main relief valve, torque converter relief valve...1914
Torque converter regulator valve...1916
ECMV...1917
Transmission...1918
Transmission control valve...1920
Lubrication relief valve...1923
Transfer...1924
Torque converter pump, transmission pump, brake cooling pump, brake pump...1926
Drive shaft...1928
Center support...1930
Differential...1932
Final drive...1936
Steering system...1938
Steering pump...1938
Switch pump...1939
Steering demand valve...1941
Diverter valve...1943
Steering cylinder mount...1944
Steering cylinder...1945
Emergency steering pump...1947
Brake system...1948
Brake valve...1948
Slack adjuster...1950
Brake...1951
Parking brake...1952
Undercarriage and frame...1954
axle mount...1954
Center hinge pin...1956
Hydraulic system...1959
No.1 work equipment pump...1959
No.2 work equipment pump...1962
PPC relief valve...1965
Pump control relief valve...1966
Work equipment control valve...1967
Work equipment...1969
Work equipment linkage...1969
Work equipment cylinder...1975
Electrical system...1977
Work equipment control lever...1977
80 Appendix...1979
Air conditioner...1981
Precautions for refrigerant...1981
Configuration and function of refrigeration cycle...1982
Outline of refrigeration cycle...1983
Control system...1985
Air conditioner components...1989
Compressor...1996
Electric fan and condenser...1997
Receiver drier...1999
Service tools...2000
Troubleshooting procedures...2007
Interview and confirmation of failure symptom...2008
Basic checks...2009
Troubleshooting...2010
Checking of refrigeration cycle...2016
Troubleshooting for unusual noise...2024
Electrical system...2025
Parts replacement...2027
Periodic inspection and maintenance...2030
Testing and adjusting compressor belt tension...2034
90 Diagrams and drawings...2035
Hydraulic circuit diagram...2037
Circuit symbols used in hydraulic circuit diagrams...2037
Transmission hydraulic circuit diagram...2040
Brake hydraulic circuit diagram...2042
Work equipment hydraulic circuit diagram...2045
Electrical circuit diagram...2047
Circuit symbols used in electrical circuit diagrams...2047
Electrical circuit diagram...2051
Index...2064
