SM Wa1200-6 60001-Up Sen05475-04 PDF

SEN05475-04
WHEEL LOADER WA1200 -6

SERIAL NUMBERS 60001 and up
Notice of revision
Notice of revision
4th revision 2012/07
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary ac-
tions must be taken to these pages according to the Q Page to be newly added Add
list below.
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List of revised pages

Revision Revision Revision Revision
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SEN0537702-00 0 -1
WA1200-6
WHEEL LOADER
Shop Manual 0-1
WA1200-6
Machine model Serial number

WA1200-6 60001 and up
00 Index and foreword 0 -1
WA1200-6 00-1
Table of Contents
Table of Contents 0 -2
00 Index and foreword

Table of contents .................................................................................................................... 00 - 2
Table of contents ................................................................................................................. 00 - 2
Foreword and general information .......................................................................................... 00- 16
Safety notice ........................................................................................................................ 00- 16
How to read the shop manual .............................................................................................. 00- 21
Explanation of terms for maintenance standard .................................................................. 00- 23
Handling of hydraulic components....................................................................................... 00- 25
Method of disconnecting and connecting push-pull type coupler ........................................ 00- 27
Handling of electric equipment............................................................................................. 00- 30
How to read electric wire code............................................................................................. 00- 40
Precautions when performing work...................................................................................... 00- 43
Standard tightening torque table.......................................................................................... 00- 46
List of abbreviation............................................................................................................... 00- 50
Conversion table .................................................................................................................. 00- 54
01 Specification
Specification............................................................................................................................ 01- 3
Specification dimension drawing.......................................................................................... 01- 3
Specifications....................................................................................................................... 01- 4
Weight table ......................................................................................................................... 01- 7
Table of fuel, coolant and lubricants .................................................................................... 01- 9
10 Structure and function

Engine and cooling system ..................................................................................................... 10- 4
Damper ................................................................................................................................ 10- 4
Cooling system .................................................................................................................... 10- 5
Cooling fan motor................................................................................................................. 10- 6
Power train.............................................................................................................................. 10- 11
Power train........................................................................................................................... 10- 11
Hydraulic piping drawing of torque converter and transmission .......................................... 10- 13
Torque converter.................................................................................................................. 10- 15
Main relief valve and torque converter relief valve............................................................... 10- 24
Torque converter regulator valve ......................................................................................... 10- 27
ECMV................................................................................................................................... 10- 29
Transmission........................................................................................................................ 10- 35
Transmission control valve .................................................................................................. 10- 46
Transmission lubricating oil relief valve ............................................................................... 10- 56
Transfer................................................................................................................................ 10- 57
Torque converter oil cooler .................................................................................................. 10- 59
Center support ..................................................................................................................... 10- 60
Axle ...................................................................................................................................... 10- 61
Final drive ............................................................................................................................ 10- 66
Steering system ...................................................................................................................... 10- 67
Steering equipment layout drawing...................................................................................... 10- 67
AJSS .................................................................................................................................... 10- 68
Steering pump...................................................................................................................... 10- 70
Switch pump ........................................................................................................................ 10- 72
Steering demand valve ........................................................................................................ 10- 89
Rotary valve ......................................................................................................................... 10- 99
EPC valve (for steering)....................................................................................................... 10- 102
00-2 WA1200-6
Table of Contents
Diverter valve....................................................................................................................... 10- 103

Emergency steering relief valve........................................................................................... 10- 106
Steering lock valve............................................................................................................... 10- 107
Brake system .......................................................................................................................... 10- 108
Brake equipment layout drawing ......................................................................................... 10- 108
Brake valve .......................................................................................................................... 10- 109
Charge valve........................................................................................................................ 10- 115
Accumulator (for brake) ....................................................................................................... 10- 119
Slack adjuster ...................................................................................................................... 10- 120
Brake ................................................................................................................................... 10- 122
Parking brake....................................................................................................................... 10- 123
Parking brake solenoid valve............................................................................................... 10- 124
Emergency parking brake release valve.............................................................................. 10- 125
Check valve of parking brake circuit .................................................................................... 10- 126
Undercarriage and frame ........................................................................................................ 10- 129
Axle mount........................................................................................................................... 10- 129
Center hinge pin .................................................................................................................. 10- 131
Jack-up point ....................................................................................................................... 10- 132
Hydraulic system .................................................................................................................... 10- 133
Hydraulic piping layout drawing ........................................................................................... 10- 133
Work equipment control lever linkage.................................................................................. 10- 135
Hydraulic tank ...................................................................................................................... 10- 136
Work equipment pump No.1 ................................................................................................ 10- 139
EPC valve (for work equipment) .......................................................................................... 10- 175
Neutral cutoff solenoid valve (NC valve).............................................................................. 10- 177
Relief valve .......................................................................................................................... 10- 179
Accumulator (for EPC valve) ............................................................................................... 10- 180
Work equipment control valve ............................................................................................. 10- 181
Work equipment...................................................................................................................... 10- 194
Work equipment linkage ...................................................................................................... 10- 194
Electrical system ..................................................................................................................... 10- 196
Machine monitor system...................................................................................................... 10- 196
Multi-function monitor .......................................................................................................... 10- 224
Work equipment and AJSS control system ......................................................................... 10- 277
Work equipment control lever .............................................................................................. 10- 312
Transmission control system ............................................................................................... 10- 315
Engine starting circuit .......................................................................................................... 10- 341
Engine stopping circuit......................................................................................................... 10- 343
Electric parking brake control .............................................................................................. 10- 347
Sensor ................................................................................................................................. 10- 357
20 Standard value table

Standard value table ............................................................................................................... 20- 3
Standard value table for engine........................................................................................... 20- 3
Standard value table for chassis.......................................................................................... 20- 4
30 Testing and adjusting

Tool for testing, adjusting and troubleshooting ....................................................................... 30- 4
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 4
Safety precautions to follow before starting work ................................................................ 30- 9
Testing engine speed .......................................................................................................... 30- 13
Testing exhaust gas color.................................................................................................... 30- 15
WA1200-6 00-3
Table of Contents
Testing blow-by pressure..................................................................................................... 30- 16

Measuring engine oil pressure............................................................................................. 30- 17
Measuring exhaust gas temperature ................................................................................... 30- 18
Testing intake air pressure (boost pressure) ....................................................................... 30- 19
Testing radiator performance............................................................................................... 30- 20
Measuring wind speed across radiator and oil cooler.......................................................... 30- 21
Testing and adjusting fan belt tension ................................................................................. 30- 22
Testing and adjusting air conditioner compressor belt tension ............................................ 30- 23
Power train.............................................................................................................................. 30- 24
Adjusting speed sensor........................................................................................................ 30- 24
Testing and adjusting torque converter and transmission oil pressure................................ 30- 26
Traction control function checking procedure ...................................................................... 30- 29
Testing torque converter oil cooler performance ................................................................. 30- 30
Testing additional cooler fan speed ..................................................................................... 30- 31
Flushing procedure for torque converter and transmission circuit ....................................... 30- 32
Retrieval of disabled machine due to transmission valve failure ......................................... 30- 33
How to measure play of center hinge bearing ..................................................................... 30- 36
Measuring wear of rear axle support ................................................................................... 30- 38
Steering system ...................................................................................................................... 30- 39
Testing and adjusting steering oil pressure ......................................................................... 30- 39
Testing and adjusting emergency steering oil pressure....................................................... 30- 40
Bleeding air from steering circuit.......................................................................................... 30- 42
Testing and adjusting steering stopper bolt ......................................................................... 30- 44
Adjusting steering follow-up linkage..................................................................................... 30- 45
Testing steering EPC valve.................................................................................................. 30- 50
Testing and adjusting steering surge cut valve oil pressure ................................................ 30- 52
Testing and adjusting steering main relief valve oil pressure .............................................. 30- 54
Testing rotary valve output pressure.................................................................................... 30- 56
Brake system .......................................................................................................................... 30- 58
Testing brake performance .................................................................................................. 30- 58
Testing lowering of wheel brake oil pressure....................................................................... 30- 59
Testing of slack adjuster ...................................................................................................... 30- 60
Mesuring wear of wheel brake disc...................................................................................... 30- 61
Testing and adjusting accumulator charge pressure ........................................................... 30- 62
Testing brake accumulator oil pressure leakage ................................................................. 30- 64
Testing emergency parking brake valve oil leakage amount ............................................... 30- 66
Testing brake valve oil leakage amount............................................................................... 30- 69
Testing brake cooling oil pressure ....................................................................................... 30- 74
Testing brake oil cooler performance................................................................................... 30- 76
Testing parking brake performance ..................................................................................... 30- 76
Testing wear of parking brake disc ...................................................................................... 30- 77
Method of releasing parking brake manually ....................................................................... 30- 78
Testing parking brake oil pressure....................................................................................... 30- 79
Testing accumulator nitrogen gas pressure and procedure for charging accumulator with
nitrogen gas ......................................................................................................................... 30- 80
Hydraulic system..................................................................................................................... 30- 86
Testing and adjusting work equipment oil pressure by using multi monitor......................... 30- 86
Testing and adjusting work equipment oil pressure by using oil pressure gauge................ 30- 88
Testing and adjusting work equipment PPC oil pressure .................................................... 30- 89
Measuring point of hydraulic pump oil pressure .................................................................. 30- 91
Testing and adjusting PV control relief valve oil pressure ................................................... 30- 95
Testing and adjusting differential valve output oil pressure ................................................. 30- 97
Testing work pump ES valve output pressure ..................................................................... 30- 99
Testing and adjusting work pump CO (cut-off) valve oil pressure ....................................... 30- 101
00-4 WA1200-6
Table of Contents
Testing and adjusting work equipment pump TVC valve oil pressure ................................. 30- 105
Operation test of work equipment valve by work equipment speed (speed of work
equipment is low)................................................................................................................. 30- 107
Testing hydraulic oil cooler performance ............................................................................. 30- 114
Bleeding air from hydraulic circuit........................................................................................ 30- 117
Releasing remaining pressure in hydraulic circuit ............................................................... 30- 122
Work equipment...................................................................................................................... 30- 123
Checking center hinge pin lubrication.................................................................................. 30- 123
Adjustment method of auto grease injector delivery ............................................................ 30- 125
Setting method of auto grease timer.................................................................................... 30- 126
Testing and adjusting bucket proximity switch..................................................................... 30- 128
Adjusting lift arm potentiometer ........................................................................................... 30- 129
Adjusting lift arm levelness detecting switch........................................................................ 30- 130
Initial setting procedure for remote boom positioner (origin input method).......................... 30- 131
Checking proximity switch operation pilot lamp ................................................................... 30- 132
Adjusting AJSS lever angle sensor and frame angle sensor ............................................... 30- 133
Testing and adjusting potentiometer mounting position ...................................................... 30- 134
Procedure for testing diodes................................................................................................ 30- 137
Basic precautions for KOMTRAX Plus controller................................................................. 30- 138
Inspection and maintenance of KOMTRAX Plus controller ................................................. 30- 147
Initial setting procedure for KOMTRAX Plus controller ........................................................ 30- 148
Precautions for replacing KOMTRAX Plus controller .......................................................... 30- 165
Measurement procedure by downloading data in KOMTRAX Plus controller ..................... 30- 173
Measurement procedure by multi monitor ........................................................................... 30- 177
Special functions of multi monitor ........................................................................................ 30- 179
Pm Clinic................................................................................................................................. 30- 236
Outline of measurement procedure for Pm Clinic ................................................................ 30- 236
Preparation for measurement for Pm Clinic......................................................................... 30- 237
Pm clinic service .................................................................................................................. 30- 238
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 8
Symptom and troubleshooting numbers .............................................................................. 40- 8
Sequence of events in troubleshooting................................................................................ 40- 9
Check before troubleshooting.............................................................................................. 40- 10
Classification and procedures of troubleshooting ................................................................ 40- 21
Breakage of hydraulic cylinder............................................................................................. 40- 24
Failure codes table .............................................................................................................. 40- 27
Information in troubleshooting table..................................................................................... 40- 44
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 46
Layout drawing of connector pins ........................................................................................ 40- 48
Connector list and layout ..................................................................................................... 40- 84
T- branch box and T- branch adapter table ......................................................................... 40- 104
Table of fuse locations......................................................................................................... 40- 107
Troubleshooting by failure code.............................................................................................. 40- 110
Failure code [1500L0] Double Engagement of Transmission Clutches ............................... 40- 110
Failure code [1540N1] T/M overrun ..................................................................................... 40- 111
Failure code [15B0NX] T/M Oil Filter Clogged..................................................................... 40- 112
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit .................................................. 40- 114
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect ......................................... 40- 116
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit.................................................. 40- 118
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect......................................... 40- 120
WA1200-6 00-5
Table of Contents
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit................................................... 40- 122
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect.......................................... 40- 124
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit................................................... 40- 126
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect.......................................... 40- 128
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit .................................................. 40- 130
Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect ......................................... 40- 132
Failure code [2F00MA] Parking brake circuit failure ............................................................ 40- 135
Failure code [2G42ZG] Accumulator Oil Press. F Low ........................................................ 40- 138
Failure code [2G43ZG] Accumulator Oil Press. R Low........................................................ 40- 140
Failure code [44K0L4] Bucket cylinder position detector SW failure ................................... 40- 142
Failure code [7REAKA] ACC Signal Malfunction ................................................................. 40- 143
Failure code [989P00] Direction protection warning ............................................................ 40- 144
Failure code [989Q00] Work equipment protection ............................................................. 40- 144
Failure code [989R00] Tire slip ............................................................................................ 40- 145
Failure code [989S00] Parking Brake Dragging................................................................... 40- 146
Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF).................................. 40- 148
Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) ................................... 40- 149
Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) ................................... 40- 150
Failure code [989W00] Stationary steering (Brake: ON, Load: ON) .................................... 40- 151
Failure code [AA1ANX] Air Cleaner 1 Clogging................................................................... 40- 152
Failure code [AA1BNX] Air Cleaner 2 Clogging................................................................... 40- 154
Failure code [AA1CNX] Air Cleaner 3 Clogging................................................................... 40- 156
Failure code [AA1DNX] Air Cleaner 4 Clogging................................................................... 40- 158
Failure code [AB00L6] Discharge of alternator R terminal................................................... 40- 160
Failure code [AB00MA] Discharge of alternator R terminal ................................................. 40- 162
Failure code [AB00MB] Discharge of alternator R terminal ................................................. 40- 164
Failure code [B@BCZK] Drop in Engine Coolant Level....................................................... 40- 166
Failure code [b@C5ZK] Low brake fluid level (before engine start) .................................... 40- 168
Failure code [B@C5ZK] Low brake fluid level (while engine is running) ............................. 40- 169
Failure code [B@C6NS] High brake oil temp....................................................................... 40- 170
Failure code [b@CENS] High torque converter oil temp. .................................................... 40- 171
Failure code [B@CENS] Very high torque converter oil temp. ............................................ 40- 172
Failure code [B@GAZK] Low battery 1 fluid level................................................................ 40- 174
Failure code [B@GBZK] Low battery 2 fluid level................................................................ 40- 176
Failure code [B@GCZK] Low battery 3 fluid level................................................................ 40- 178
Failure code [B@HANS] High hydraulic oil temp................................................................. 40- 180
Failure code [B@HAZK] Low hydraulic oil level................................................................... 40- 181
Failure code [D191KA] Neutral Output Relay Disconnection............................................... 40- 182
Failure code [D191KB] Neutral Output Relay hot short ....................................................... 40- 184
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit) ............ 40- 186
Failure code [D19MKY] SW pump PNC solenoid Relay hot short....................................... 40- 188
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure ...................................... 40- 190
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure ...................................... 40- 192
Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)............. 40- 194
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short ....................................... 40- 196
Failure code [D5ZHKZ] Starting Switch C signal circuit failure ............................................ 40- 198
Failure code [D5ZHL6] Ignition C terminal Circuit Failure.................................................... 40- 200
Failure code [DAF5KP] Monitor Panel 5 V source sys Error ............................................... 40- 202
Failure code [DAFRKR] Communication Lost Monitor Panel Controller.............................. 40- 204
Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source.................... 40- 206
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal.................................... 40- 208
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source ............. 40- 210
Failure code [DAQRKR] Communication Lost T/M Controller ............................................. 40- 212
Failure code [DAQRMA] Defective Option Selection Data in Transmission ........................ 40- 214
00-6 WA1200-6
Table of Contents
Failure code [DB2RKR] Communication Lost Engine Controller......................................... 40- 216

Failure code [DB90KK] Drop in Work Controller Main Power Source ................................. 40- 218
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal .................................... 40- 220
Failure code [DB92KK] Solenoid Voltage Failure (Work controller) .................................... 40- 222
Failure code [DB95KX] 5 V source sys Error (Work controller) ........................................... 40- 224
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller ............ 40- 226
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller ........ 40- 228
Failure code [DB9RMC] Communication Lost (Work Controller)......................................... 40- 230
Failure code [DBB0KK] VHMS source voltage Error ........................................................... 40- 232
Failure code [DBB0KQ] VHMS Connector Mismatch .......................................................... 40- 234
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V) ........................ 40- 236
Failure code [DBB5KP] VHMS 5 V source sys Error ........................................................... 40- 238
Failure code [DBB6KP] VHMS 24 V source sys Error ......................................................... 40- 240
Failure code [DBBQMC] Communication Lost (VHMS CAN0) ............................................ 40- 243
Failure code [DBBRKR] Communication Lost VHMS Controller ......................................... 40- 245
Failure code [DBBRMC] Communication Lost (VHMS CAN1) ............................................ 40- 246
Failure code [DD10KX] Verification Mode SW Failure ........................................................ 40- 248
Failure code [DD1ALD] Remote positioner upper side set sw failure .................................. 40- 250
Failure code [DD1BLD] Remote positioner lower side set sw failure .................................. 40- 252
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit .......................................... 40- 254
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit ....................... 40- 256
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit....................... 40- 258
Failure code [DDB6L4] Neutral Signal Malfunction ............................................................. 40- 260
Failure code [DDD7KA] Speed control dial circuit (Low Voltage) ........................................ 40- 262
Failure code [DDD7KB] Speed control dial circuit (High Voltage) ....................................... 40- 264
Failure code [DDDBKA] Traction control dial circuit (Low Voltage) ..................................... 40- 266
Failure code [DDDBKB] Traction control dial circuit (High Voltage) .................................... 40- 268
Failure code [DDE5MA] Emergency steering signal Failure................................................ 40- 270
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection........................................ 40- 272
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit .......................................... 40- 274
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)......... 40- 276
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect .. 40- 278
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit ...................................... 40- 280
Failure code [DDW9LD] Kickdown Switch Short Circuit ...................................................... 40- 282
Failure code [DGE5KX] Ambient air temp Sensor Failure................................................... 40- 284
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect ............. 40- 286
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit 40- 288
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check) .......... 40- 290
Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure........................................ 40- 292
Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection ................................ 40- 294
Failure code [DGR2KX] Brake oil temp. sensor circuit failure ............................................. 40- 296
Failure code [DGT1KX] T/C oil temp. sensor circuit failure ................................................. 40- 298
Failure code [DH20KX] Torque converter pressure sensor circuit ...................................... 40- 300
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit).............. 40- 302
Failure code [DH21KB] Loader pump oil press sensor hot short......................................... 40- 304
Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit) ............................ 40- 306
Failure code [DHPCKX] Boom bottom press. sensor circuit failure..................................... 40- 308
Failure code [DHPCKY] Boom bottom press. hot short....................................................... 40- 310
Failure code [DHPDKX] Boom head press. sensor circuit failure ........................................ 40- 312
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect ............................ 40- 314
Failure code [DHT2L6] T/M oil filter sensor circuit failure .................................................... 40- 316
Failure code [DHT3KX] Transmission main pressure sensor circuit ................................... 40- 318
Failure code [DHT4KX] Main PPC oil pressure sensor circuit ............................................. 40- 320
WA1200-6 00-7
Table of Contents
Failure code [DHT5KX] Torque converter intake pressure sensor circuit............................ 40- 322
Failure code [DHT8KX] Steering Oil Press. Sensor Failure................................................. 40- 324
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit........................... 40- 326
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect................... 40- 328
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit .................. 40- 330
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect............................................ 40- 332
Failure code [DHU2KB] F Brake Oil press Sensor Hot short............................................... 40- 334
Failure code [DHU2KX] F Brake Oil press Sensor Failure .................................................. 40- 336
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect ........................................... 40- 338
Failure code [DHU3KB] R Brake Oil press Sensor Hot short .............................................. 40- 340
Failure code [DHU3KX] R Brake Oil press Sensor Failure .................................................. 40- 341
Failure code [DJF1KA] Fuel level sensor circuit Disconnection........................................... 40- 343
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit).................. 40- 344
Failure code [DK30KY] Steering lever angle sensor circuit hot short .................................. 40- 345
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit) ......... 40- 346
Failure code [DK59KY] Boom lever potentiometer (main) hot short .................................... 40- 348
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure............................... 40- 349
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)........... 40- 352
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short...................................... 40- 354
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit) ....... 40- 356
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short .................................. 40- 358
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure............................. 40- 359
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)......... 40- 362
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short.................................... 40- 363
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) .............................. 40- 364
Failure code [DKA0KX] Boom angle sensor circuit failure................................................... 40- 366
Failure code [DKA0KY] Boom angle sensor circuit hot short............................................... 40- 368
Failure code [DKA0L0] Boom angle sensor failure .............................................................. 40- 370
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)............................. 40- 372
Failure code [DKD0KY] Frame angle sensor circuit hot short ............................................. 40- 373
Failure code [DKD0KZ] Frame and steering angle sensor failure ....................................... 40- 374
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect ............................................ 40- 375
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short................................................ 40- 376
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect............................................. 40- 378
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short................................................ 40- 380
Failure code [DLE2KA] Engine Speed Sensor Disconnection............................................. 40- 382
Failure code [DLE2LC] Engine Speed Sensor Short Circuit................................................ 40- 384
Failure code [DLF6LC] Tire speed sensor circuit................................................................. 40- 386
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect ....................................... 40- 388
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit ..................................... 40- 390
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit ................................. 40- 392
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection............................... 40- 394
Failure code [DT20KB] Transmission cut off indicator Output short circuit.......................... 40- 396
Failure code [DT21KB] Speed Control indicator Output short circuit................................... 40- 397
Failure code [DUM8KB] VHMS Operation lamp Short Circuit ............................................. 40- 398
Failure code [DV00KY] Buzzer circuit hotshort (for usually) ................................................ 40- 400
Failure code [DV01KY] Buzzer circuit hotshort (for special) ................................................ 40- 402
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection......................... 40- 404
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit............................ 40- 405
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short ...................... 40- 406
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection ........................ 40- 407
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit ........................... 40- 408
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short ...................... 40- 409
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection ...................... 40- 410
00-8 WA1200-6
Table of Contents
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit ......................... 40- 411
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short.................... 40- 412
Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection ................................. 40- 413
Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault .................................. 40- 414
Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short ....................................... 40- 415
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection .............................. 40- 416
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit ............................ 40- 417
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short ................................ 40- 418
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection................................... 40- 419
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault...................................... 40- 420
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short........................................... 40- 421
Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection ................................. 40- 422
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit ................................. 40- 423
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...................................... 40- 424
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection ........................ 40- 428
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault ................................. 40- 429
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short ...................................... 40- 430
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection ...................................... 40- 431
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault ........................................... 40- 432
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short .............................................. 40- 433
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit..................................... 40- 435
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short ......................................... 40- 436
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection ............................ 40- 437
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit............................... 40- 438
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short ......................... 40- 439
Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection .................. 40- 440
Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit...................... 40- 441
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short .......................... 40- 442
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection.................... 40- 443
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit ....................... 40- 444
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short............................ 40- 445
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection..................... 40- 446
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit ........................ 40- 447
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short............................. 40- 448
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection ...................... 40- 449
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit ........................... 40- 450
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short................................ 40- 451
Failure code [DWNAKA] NC solenoid disconnection........................................................... 40- 452
Failure code [DWNAKB] NC solenoid short circuit .............................................................. 40- 453
Failure code [DWNAKY] NC solenoid hot short................................................................... 40- 454
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit) ............... 40- 455
Failure code [DXA1KY] Loader pump solenoid Relay hot short .......................................... 40- 457
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit) .............. 40- 459
Failure code [DXF0KA] AJSS EPC solenoid disconnection ................................................ 40- 461
Failure code [DXF0KB] AJSS EPC solenoid short circuit.................................................... 40- 463
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection................................... 40- 465
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit...................................... 40- 467
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short ................................ 40- 469
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection.................................. 40- 471
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit .................................... 40- 473
WA1200-6 00-9
Table of Contents
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short ............................... 40- 475
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection................................... 40- 477
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit ..................................... 40- 479
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short ................................ 40- 481
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection ..................................... 40- 483
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit ........................................ 40- 485
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short................................... 40- 487
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection...................................... 40- 489
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit ........................................ 40- 491
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short ................................... 40- 493
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection ........................... 40- 494
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit .............................. 40- 495
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V.................. 40- 496
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction ............................... 40- 497
Troubleshooting of electrical system (E-mode),...................................................................... 40- 499
E-1 Remote positioner "RAISE" or "LOWER" LED does not light up................................... 40- 499
E-2 Open circuit or ground fault in check lamp system........................................................ 40- 500
E-3 Machine monitor does not operate................................................................................ 40- 501
E-4 Turn signal lamp does not light up ................................................................................ 40- 502
E-5 Defective parking lamp.................................................................................................. 40- 504
E-6 Defective front working lamp ......................................................................................... 40- 506
E-7 Defective rear working lamp.......................................................................................... 40- 508
E-8 Headlamp does not light up........................................................................................... 40- 510
E-9 Service meter does not work, or service meter works while engine is stopped. ........... 40- 512
E-10 Monitor panel controller does not sound buzzer ......................................................... 40- 514
E-11 Defective auto-greasing system .................................................................................. 40- 516
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 518
Before performing troubleshooting of work equipment hydraulic system (how to use the
multi monitor) ....................................................................................................................... 40- 518
Work equipment hydraulic system, general ......................................................................... 40- 528
Work equipment oil pressure group ..................................................................................... 40- 530
Before performing troubleshooting of steering oil pressure system (how to use the multi
monitor)................................................................................................................................ 40- 595
Checking steering related standard values.......................................................................... 40- 608
Steering oil pressure system, general.................................................................................. 40- 609
Steering oil pressure group.................................................................................................. 40- 610
Brake oil pressure system, general...................................................................................... 40- 650
Brake oil pressure group...................................................................................................... 40- 651
Information contained in troubleshooting table (H mode) .................................................... 40- 701
H-1 Torque converter oil temperature rises too high (overheats) ........................................ 40- 702
H-2 Turning or response of steering is poor ........................................................................ 40- 705
H-3 AJSS lever is hard to operate ....................................................................................... 40- 708
H-4 Steering shakes or jolts................................................................................................. 40- 710
H-5 Wheel brake does not work at all or is weak................................................................. 40- 712
H-6 Lift arm speed is low or lift arm rising force is insufficient ............................................. 40- 714
H-7 Shock is large when lift arm stops................................................................................. 40- 717
H-8 Hydraulic oil temperature rises too high (overheating).................................................. 40- 718
50 Disassembly and assembly

General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Coating materials list............................................................................................................ 50- 6
Special tool list ..................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 14
00-10 WA1200-6
Table of Contents
Flushing procedure ................................................................................................................. 50- 54

Flushing procedure for brake circuit .................................................................................... 50- 54
Flushing procedure for work equipment and steering circuit ............................................... 50- 60
Air bleeding procedure............................................................................................................ 50- 66
Bleeding air from brake circuit ............................................................................................. 50- 66
Bleeding air from piston pump ............................................................................................. 50- 68
Bleeding air from work equipment circuit and steering circuit.............................................. 50- 69
Removal and installation of radiator and hydraulic oil cooler assembly .............................. 50- 72
Removal and installation of engine assembly...................................................................... 50- 79
Removal and installation of air-cooled torque converter and transmission,
and brake oil cooler assembly .............................................................................. 50- 86
Removal and installation of water-cooled torque converter and transmission
oil cooler assembly ............................................................................................... 50- 88
Removal and installation of damper assembly .................................................................... 50- 89
Disassembly and assembly of damper ................................................................................ 50- 91
Removal and installation of bumper and fuel tank assembly............................................... 50- 98
Removal and installation of hood assembly ........................................................................ 50- 100
Disassembly and assembly procedures for MESABI oil cooler ........................................... 50- 102
Disassembly and assembly of MESABI oil cooler ............................................................... 50- 105
Power train.............................................................................................................................. 50- 113
Removal and installation of torque converter and transmission assembly .......................... 50- 113
Disconnection and connection of transmission assembly and torque converter assembly . 50- 120
Disconnection and connection of torque converter assembly, PTO and transfer assembly 50- 127
Disassembly and assembly of torque converter .................................................................. 50- 131
Disassembly and assembly of modulation clutch ................................................................ 50- 142
Disassembly and assembly of PTO and transfer................................................................. 50- 146
Disconnection and connection of transmission assembly, transfer, and parking
brake assembly .................................................................................................... 50- 159
Disassembly and assembly of transmission assembly ........................................................ 50- 166
Disassembly and assembly of transfer ................................................................................ 50- 187
Disassembly and assembly of parking brake ...................................................................... 50- 194
Removal and installation of parking brake assembly (installed on the machine) ................ 50- 197
Removal and installation of transmission, brake cooling device and brake pump assembly 50- 201
Removal and installation of steering pump, control pump and PPC pump assembly ......... 50- 202
Disassembly and assembly of drive shaft............................................................................ 50- 203
Removal and installation of front axle assembly.................................................................. 50- 205
Removal and installation of front final drive assembly ......................................................... 50- 207
Removal and installation of rear axle assembly .................................................................. 50- 209
Removal and installation of rear final drive assembly.......................................................... 50- 220
Removal and installation of differential assembly ................................................................ 50- 223
Disassembly and assembly of differential............................................................................ 50- 225
Disassembly and assembly of final drive and brake ............................................................ 50- 238
Removal and installation of center support assembly ......................................................... 50- 251
Disassembly and assembly of center support ..................................................................... 50- 253
Steering system ...................................................................................................................... 50- 257
Removal and installation of steering demand valve assembly ............................................ 50- 257
Removal and installation of steering cylinder assembly ...................................................... 50- 258
Removal and installation of emergency diverter valve assembly ........................................ 50- 262
Removal and installation of emergency steering pump assembly ....................................... 50- 264
Brake system .......................................................................................................................... 50- 265
Removal and installation of brake accumulator charge valve assembly ............................. 50- 265
Removal and installation of brake oil tank assembly ........................................................... 50- 266
WA1200-6 00-11
Table of Contents

Procedure for disconnecting front frame and rear frame ..................................................... 50- 267
Removal and installation of center hinge pin ....................................................................... 50- 268
Removal and installation of hydraulic tank, filter case assembly ......................................... 50- 284
Removal and installation of No. 1 work equipment pump assembly.................................... 50- 286
Removal and installation of No. 2 work equipment pump assembly.................................... 50- 288
Removal and installation of switch pump assembly............................................................. 50- 289
Removal and installation of work equipment control valve assembly .................................. 50- 290
Work equipment...................................................................................................................... 50- 304
Removal and installation of bucket cylinder assembly......................................................... 50- 304
Removal and installation of lift cylinder assembly................................................................ 50- 315
Disassembly and assembly of work equipment cylinder...................................................... 50- 329
Removal and installation of work equipment assembly ....................................................... 50- 335
Procedure for running in bucket pin ..................................................................................... 50- 391
Procedure for running in lift arm pin..................................................................................... 50- 393
Cab ......................................................................................................................................... 50- 396
Removal and installation of bulkhead assembly .................................................................. 50- 396
Removal and installation of operator's cab and floor assembly ........................................... 50- 398
Removal and installation of operator's cab assembly .......................................................... 50- 402
Removal and installation of air conditioner unit assembly ................................................... 50- 404
Disassembly and assembly of operator seat ....................................................................... 50- 406
Removal and installation of DT connector pin ..................................................................... 50- 439
Removal and installation of HD connector pin ..................................................................... 50- 441
Repairing HD connector pin harness ................................................................................... 50- 442
Removal and installation of controller assembly.................................................................. 50- 443
60 Maintenance standard
Engine mount....................................................................................................................... 60- 3
Cooling system .................................................................................................................... 60- 4
Damper ................................................................................................................................ 60- 7
Power train.............................................................................................................................. 60- 8
Transmission mount............................................................................................................. 60- 8
Main relief valve, torque converter relief valve..................................................................... 60- 14
ECMV................................................................................................................................... 60- 17
Transmission........................................................................................................................ 60- 18
Lubrication relief valve ......................................................................................................... 60- 23
Transfer................................................................................................................................ 60- 24
Torque converter pump, transmission pump, brake cooling pump, brake pump ................. 60- 26
Drive shaft............................................................................................................................ 60- 28
Center support ..................................................................................................................... 60- 30
Differential............................................................................................................................ 60- 32
Final drive ............................................................................................................................ 60- 36
Steering system ...................................................................................................................... 60- 38
Steering pump...................................................................................................................... 60- 38
Switch pump ........................................................................................................................ 60- 39
Diverter valve ....................................................................................................................... 60- 43
00-12 WA1200-6
Table of Contents
Steering cylinder mount ....................................................................................................... 60- 44

Steering cylinder .................................................................................................................. 60- 45
Emergency steering pump................................................................................................... 60- 47
Brake system .......................................................................................................................... 60- 48
Brake valve .......................................................................................................................... 60- 48
Slack adjuster ...................................................................................................................... 60- 50
Brake ................................................................................................................................... 60- 51
Parking brake....................................................................................................................... 60- 52
axle mount ........................................................................................................................... 60- 54
Center hinge pin .................................................................................................................. 60- 56
No.1 work equipment pump................................................................................................. 60- 59
No.2 work equipment pump................................................................................................. 60- 62
PPC relief valve ................................................................................................................... 60- 65
Pump control relief valve ..................................................................................................... 60- 66
Work equipment...................................................................................................................... 60- 69
Bucket positioner, remote positioner ................................................................................... 60- 74
Work equipment cylinder ..................................................................................................... 60- 75
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Configuration and function of refrigeration cycle ................................................................. 80- 4
Outline of refrigeration cycle ................................................................................................ 80- 5
Control system..................................................................................................................... 80- 7
Air conditioner components ................................................................................................. 80- 11
Compressor ......................................................................................................................... 80- 18
Electric fan and condenser .................................................................................................. 80- 19
Receiver drier ...................................................................................................................... 80- 21
Service tools ........................................................................................................................ 80- 22
Troubleshooting procedures ................................................................................................ 80- 29
Interview and confirmation of failure symptom .................................................................... 80- 30
Basic checks........................................................................................................................ 80- 31
Troubleshooting ................................................................................................................... 80- 32
Checking of refrigeration cycle ............................................................................................ 80- 38
Troubleshooting for unusual noise....................................................................................... 80- 46
Electrical system.................................................................................................................. 80- 47
Parts replacement................................................................................................................ 80- 49
Periodic inspection and maintenance .................................................................................. 80- 52
Testing and adjusting compressor belt tension ................................................................... 80- 56
90 Diagrams and drawings

Hydraulic circuit diagram ........................................................................................................ 90- 3
Circuit symbols used in hydraulic circuit diagrams .............................................................. 90- 3
Transmission hydraulic circuit diagram................................................................................ 90- 6
Brake hydraulic circuit diagram............................................................................................ 90- 8
Work equipment hydraulic circuit diagram........................................................................... 90- 11
Electrical circuit diagram ......................................................................................................... 90- 15
Circuit symbols used in electrical circuit diagrams .............................................................. 90- 15
WA1200-6 00-13
Table of Contents
Electrical circuit diagram ...................................................................................................... 90- 19
Index ....................................................................................................................................... 1
00-14 WA1200-6
Table of Contents
WA1200-6 00-15
Foreword and general information
Safety notice
Foreword and general information 0 -16

Safety notice 0 -16
Important safety notice
Appropriate servicing and repair are extremely important to ensure safe operation of the machine.
The shop manuals describe the effective and safe servicing and repair methods recommended by Ko-
matsu. Some of the servicing and repair methods require use of special tools designed by Komatsu
for special purposes.
The symbol mark "k" is indicated for such matters that require special precautions. The work indi-
cated with the warning mark should be performed according to the instructions with special attention
to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure
to keep safe first and take every necessary measure.
1. General precautions
kInappropriate handling creates an extreme 7)If welding repairs are needed, always have a
danger. Read and understand what is de- trained and experienced welder perform the
scribed in the Operation and Maintenance work. When performing welding work, always
Manual before operating the machine. wear welding gloves, apron, shielding
Read and understand what is described in goggles, cap and other clothes suited for
this manual before starting work. welding work.
1)Before performing any greasing or repairs, 8)Before starting work, warm up your body thor-
read all the safety labels stuck to the oughly to start work under good condition.
machine. For the locations of the safety 9)Avoid continuing work for long hours and take
labels and detailed explanation of precau- rests at proper intervals to keep your body in
tions, see the Operation and Maintenance good condition and at the provided place.
Manual.
2)Locate a place in the repair workshop to keep Safety points
tools and removed parts. Always keep the 1 Good arrangement
tools and parts in their correct places. Always 2 Correct work clothes
keep the work area clean and make sure that 3 Following work standard
there is no dirt, water, or oil on the floor. 4 Making and checking signals
5 Prohibition of operation and handling by unli-
Smoke only in the areas provided for
censed workers
smoking. Never smoke while working. 6 Safety check before starting work
3)When performing any operation, always wear 7 Wearing protective goggles (for cleaning or grind-
safety shoes and helmet. Do not wear loose ing work)
work clothes, or clothes with buttons missing. 8 Wearing shielding goggles and protectors (for
qAlways wear the safety glasses when hitting welding work)
parts with a hammer. 9 Good physical condition and preparation
qAlways wear the safety glasses when grind- 10 Precautions against work which you are not used
ing parts with a grinder, etc. to or you are used to too much
4)When performing any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform
your fellow workers before starting any step
of the operation. Before starting work, hang
UNDER REPAIR warning tag in the oper-
ator's compartment.
5)Only qualified workers must perform the work
and operation which require license or quali-
fication.
6)Keep all tools in good condition, learn the
correct way to use them, and use the proper
ones. Before starting work, thoroughly check
the tools, machine, forklift truck, service car,
etc.
00-16 WA1200-6
(02)
Safety notice
2. Preparation work
1)Before adding oil or making any repairs, park
the machine on a hard and level ground, and
apply the parking brake and chock the
wheels or tracks to prevent the machine from
moving.
2)Before starting work, lower the work equip-
ment (blade, ripper, bucket, etc.) to the
ground. If this is not possible, insert the lock
pin or use blocks to prevent the work equip-
ment from falling. In addition, be sure to lock
all the control levers and hang warning tag on
them.
3)When disassembling or assembling, support
the machine with blocks, jacks, or stands
before starting the work. 5)When raising a heavy component (heavier
4)Remove all mud and oil from the steps or other than 25 kg), use a hoist or crane. Before
places used to get on and off the machine. starting work, check that the slings (wire
Always use the handrails, ladders or steps ropes, chains, and hooks) are free from
when getting on or off the machine. Never damage. Always use slings which have
jump on or off the machine. If it is impossible ample capacity and install them to proper
to use the handrails, ladders or steps, use a places. Operate the hoist or crane slowly to
stand to provide safe footing. prevent the component from hitting any other
part. Do not work with any part still raised by
3. Precautions during work the hoist or crane.
1)Before disconnecting or removing compo- 6)When removing a cover which is under internal
nents for the oil, water, or air circuits, first pressure or under pressure by a spring,
release the pressure completely from the always leave two bolts in diagonal positions.
circuit. When removing the oil filler cap, a Loosen those bolts gradually and alternately
drain plug, or an oil pressure pickup plug, to release the pressure, and then remove the
loosen it slowly to prevent the oil from cover.
spurting out. 7)When removing components, be careful not to
2)The coolant and oil in the circuits are hot when break or damage the electrical wiring.
the engine is shut down, so be careful not to Damaged wiring may cause electrical fires.
get scalded. Wait for the oil and coolant to 8)When removing piping, stop the fuel or oil from
cool before performing any work on the oil or spilling out. If any fuel or oil drips onto the
water circuits. floor, wipe it off immediately. Fuel or oil on
3)Before starting work, shut down the engine. the floor can cause you to slip and can even
When working on or around a rotating part, in cause fires.
particular, shut down the engine. When 9)As a general rule, do not use gasoline to wash
checking the machine without shutting down parts. Do not use it to clean electrical parts,
the engine (measuring oil pressure, revolving in particular.
speed, temperature, etc.), take extreme care 10)Be sure to assemble all parts again in their
not to get caught in rotating parts or moving original places. Replace any damaged parts
parts. and parts which must not be reused with new
4)For the machine equipped with a battery parts. When installing hoses and wires, be
disconnct switch, turn the battery discon- sure that they will not be damaged by contact
nect switch to the OFF (O) position and with other parts when the machine is oper-
pull the switch key out, before starting the ated.
work. For machines without a battery 11)When installing high pressure hoses and
disconnct switch, remove the cable from the tubes, make sure that they are not twisted.
battery , before starting the work. Always Damaged hoses and tubes are dangerous,
remove the cable from the negative (-) so be extremely careful when installing
terminal first. hoses and tubes for high pressure circuits. In
addition, check that connections of them are
correct.
WA1200-6 00-17
(02)
Safety notice
12)When assembling or installing parts, always 7)Limit the hanging angle to 60 degree, as a rule.
tighten them to the specified torques. When Do not sling a heavy load (25 kg or more)
installing protective parts such as guards, or with ropes forming a wide hanging angle
parts which vibrate violently or rotate at high from the hook.
speeds, be particularly careful to check that When hoisting a load with two or more ropes,
they are installed correctly. the force subjected to each rope will increase
13)When aligning two holes, never insert your with the hanging angle. The table below
fingers or hand. Be careful not to get your shows the variation of allowable load in kN
fingers caught in a hole. {kg} when hoisting is made with two ropes,
14)When measuring hydraulic pressure, check each of which is allowed to sling up to 9.8 kN
that the measuring tools are correctly {1,000 kg} vertically, at various hanging
installed. angles. When the two ropes sling a load verti-
15)Take care when removing or installing the cally, up to 19.6 kN {2,000 kg} of total weight
tracks of track-type machines. When can be suspended. This weight is reduced to
removing the track, the track separates 9.8 kN {1,000 kg} when the two ropes make
suddenly, so never let anyone stand at either a hanging angle of 120 degree. If the two
end of the track. ropes sling a 19.6 kN {2,000 kg} load at a
16)If the engine is operated for a long time in a lifting angle of 150 degree, each of them is
place which is not ventilated well, you may subjected to a force as large as 39.2 kN
suffer from gas poisoning. Accordingly, open {4,000 kg}.
the windows and doors to ventilate well.
4. Precautions for slinging work and making

signals
1)Only one appointed worker must make signals
and co-workers must communicate with each
other frequently. The appointed signaler
must make specified signals clearly at a
place where he is well seen from the oper-
ator's seat and where he can see the working
condition easily. The signaler must always
stand in front of the load and guide the oper-
ator safely.
qDo not stand under the load.
qDo not step on the load.
8)When installing wire ropes to an angular load,
2)Check the slings before starting sling work. apply pads to protect the wire ropes. If the
3)Keep putting on gloves during sling work. (Put load is slippery, apply proper material to
on leather gloves, if available.) prevent the wire rope from slipping.
4)Measure the weight of the load by the eye and 9)Use the specified eyebolts and fix wire ropes,
check its center of gravity. chains, etc. to them with shackles, etc.
5)Use proper sling according to the weight of the 10)Apply wire ropes to the middle portion of the
load and method of slinging. If too thick wire hook.
ropes are used to sling a light load, the load qSlinging near the tip of the hook may cause
may slip and fall. the rope to slip off the hook during hoist-
6)Do not sling a load with one wire rope alone. If ing. The hook has the maximum strength
it is slung so, It may rotate and may slip out at the middle portion.
of the rope. Install two or more wire ropes
symmetrically.
kSlinging with one rope may cause turn-
ing of the load during hoisting, un-
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
00-18 WA1200-6
(02)
Safety notice
4)Check the direction indicator plates (east,

west, south, and north) and the directions of
the control buttons without fail.
5)Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6)Do not raise or lower a load while the crane is
moving longitudinally or laterally.
7)Do not drag a sling.
8)When lifting up a load, stop it just after it leaves
the ground and check safety, and then lift it
up.
9)Consider the travel route in advance and lift up
a load to a safe height.
10)Place the control switch in a position where it
11)Do not use twisted or kinked wire ropes. will not be an obstacle to work and passage.
12)When lifting up a load, observe the following. 11)After operating the hoist, do not swing the
qWind in the crane slowly until wire ropes are
control switch.
stretched. When settling the wire ropes 12)Remember the position of the main switch so
with the hand, do not grasp them but that you can turn off the power immediately in
press them from above. If you grasp an emergency.
them, your fingers may be caught. 13)If the hoist stops because of a power failure,
qAfter the wire ropes are stretched, stop the
turn the power switch OFF. When turning on
crane and check the condition of the a switch which was turned OFF by the
slung load, wire ropes, and pads. ground fault circuit interrupter, check that the
qIf the load is unstable or the wire rope or
devices related to that switch are not in oper-
chains are twisted, lower the load and lift ating condition.
it up again. 14)If you find an obstacle around the hoist, stop
qDo not lift up the load at an angle.
the operation.
13)When lowering a load, observe the following. 15)After finishing the work, stop the hoist at the
qWhen lifting down a load, stop it temporarily
specified position and raise the hook to at
at 30 cm above the floor, and then lower least 2 m above the floor. Do not leave the
it slowly. sling installed to the hook.
qCheck that the load is stable, and then re-
move the sling. 7. Selecting wire ropes
qRemove kinks and dirt from the wire ropes
1)Select adequate ropes depending on the
and chains used for the sling work, and weight of parts to be hoisted, referring to the
put them in the specified place. table below
Wire ropes
(Standard "Z" twist ropes without galvanizing)
5. Precautions for using mobile crane
(JIS G3525, No. 6, Type 6X37-A)
aRead the Operation and Maintenance Manual Nominal diameter Allowable load
of the crane carefully in advance and operate of rope
the crane safely. mm kN ton
10 8.8 0.9
6. Precautions for using overhead traveling 12 12.7 1.3
crane 14 17.3 1.7
kA hoist crane or similar device must be
16 22.6 2.3
18 28.6 2.9
used for lifting a heavy load (25 kg or
20 35.3 3.6
more). The weight of a part that is 25 kg or 25 55.3 5.6
more is indicated with the symbol "4" in 30 79.6 8.1
"Disassembly and assembly". 40 141.6 14.4
1)Before starting work, inspect the wire ropes, 50 221.6 22.6
brake, clutch, controller, rails, over wind stop 60 318.3 32.4
device, ground fault circuit interrupter, crane aThe allowable load is one-sixth of the
collision prevention device, and power appli- breaking strength of the rope to be used
cation warning lamp, and check safety. (Safety coefficient: 6).
2)Observe the signals for sling work.
3)Operate the hoist at a safe place.
WA1200-6 00-19
(02)
Safety notice
8. Precautions for disconnecting and aFor tightening torque, see the precau-
connecting hoses and tubes in an air conditions for installation in each section of
tioner circuit "Disassembly and assembly".
1)Disconnection
kAlthough the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friend-
liness, it is not allowed to be released
into the atmosphere as is. Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refriger-
ant gas to reuse it.
aAsk a qualified person for collection and
charge of the refrigerant (R134a).
aNever release the refrigerant (R134a) to
the atmosphere.
kIf the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.
Whenever recovering or adding refrig-
erant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.
2)Connection
1]When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2]When connecting the air conditioner hoses
and tubes, check that O-rings (1) are
fitted to their joints.
3]Check that O-ring (1) is free from flaw and
deterioration.
4]When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings.
aExample of O-ring (Fitted to every joint
of hoses and tubes)
00-20 WA1200-6
(02)
How to read the shop manual
How to read the shop manual 0 -21

(Rev. 2010/03)
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard

This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
WA1200-6 00-21
How to read the shop manual
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.
q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)
q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
4. Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Description
k
Special safety precautions which are necessary when performing work are
Safety
described.
Special technical precautions or other precautions for preserving standards which

a Caution
are necessary when performing work are described.
4
Weight of parts of component or parts are indicated. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc. are described.
3
Places that require special attention for tightening torque during assembly are
Tightening torque
indicated.
2 Coat Places to be coated with adhesives, etc. during assembly are indicated.
5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.
6 Drain Places where oil, etc. must be drained, and quantity to be drained are indicated.
5. Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00-22 WA1200-6
Explanation of terms for maintenance standard
Explanation of terms for maintenance standard 0 -23

(Rev. 2010/03)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.
1. Standard dimension and tolerance qWhen some parts are repaired, the value of
qTo be accurate, the finished dimension of parts performance/function is set to the standard
is slightly different from one to another. value.
qTo specify the finished dimension of a part, a
certain dimension is set for the part and an al-
lowable difference from that dimension is in-
dicated.
qThe above dimension set is called the "stan-
dard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
qThe tolerance with the symbols of + or – is indi-
cated on the right side of the standard dimen-
sion.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
aThe tolerance may be indicated in the text and
a table as [standard dimension (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
qUsually, the dimension of a hole and the dimen-

sion of the shaft to be inserted into that hole
are indicated by the same standard dimen-
sion and different tolerances of the hole and
shaft. The tightness of fit is decided by the
tolerance.
qIndication of dimension of rotating shaft and
hole and their related drawing.
3. Standard interference
Example: qWhen the diameter of a hole of a part shown in
Tolerance
Standard dimension the given standard dimension and tolerance
Shaft Hole
-0.030 +0.046 table is smaller than that of the shaft to be in-
60 serted, the difference between those diame-
-0.076 0
ters is called the "interference".
qThe range (between A and B) from the differ-
2. Standard clearance and standard value ence (A) between the minimum dimension of
qThe clearance made when new parts are as-
the shaft and the maximum dimension of the
sembled is called the "standard clearance", hole to the difference (B) between the maxi-
which is indicated by the range from the min- mum dimension of the shaft and the mini-
imum clearance to the maximum clearance. mum dimension of the hole is the “standard
qWhen some parts are repaired, the clearance is
interference”.
generally adjusted to the standard clearance. qAfter repairing or replacing some parts, mea-
qThe values indicating performance and func-
sure the dimension of their hole and shaft
tion of new products or equivalent are called and check that the interference is in the stan-
the "standard value", which is indicated by a dard range.
range or a target value.
WA1200-6 00-23
Explanation of terms for maintenance standard
4. Repair limit and allowable value or allowable

dimension
qThe dimension of a part changes because of
wear and deformation while it is used. The
limit of changed dimension is called the "re-
pair limit".
qIf a part is worn to the repair limit, it must be re-
placed or repaired.
qThe performance and function of a product low-
ers while it is used. A value with which the
product can be used without causing a prob-
lem is called the "allowable value" or "allow-
able dimension".
qIf a product deviates from the allowable value,
it must be checked or repaired. However,
since most of the allowable values are esti-
mated from various tests or experiences in
most cases, it must be judged after consider-
ing the operating condition and customer's
requirement.
5. Allowable clearance
qParts can be used until the clearance between
them is increased to a certain limit. The limit
at which those parts cannot be used is called
the "allowable clearance".
qIf the clearance between the parts exceeds the
allowable clearance, they must be replaced
or repaired.
6. Allowable interference
qThe allowable maximum interference between
the hole of a part and the shaft of another part
to be assembled is called the "allowable in-
terference".
qThe allowable interference shows the repair
limit of the part of smaller tolerance.
qIf the interference between the parts exceeds
the allowable interference, they must be re-
placed or repaired.
00-24 WA1200-6
Handling of hydraulic components
Handling of hydraulic components 0 -25

(Rev. 2010/03)
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.
1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
4. Preventing intrusion of foreign materials

during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.
WA1200-6 00-25
Handling of hydraulic components
5. Replacing hydraulic oil while its temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
hole in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-26 WA1200-6
Method of disconnecting and connecting push-pull type coupler
Method of disconnecting and connecting push-pull type coupler 0 -27

(Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 0 -2 7
1. Disconnection
1)Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
aThe adapter can be pushed in about 3.5
mm.
aDo not hold rubber cap portion (4).
2)With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3)Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
aSince some hydraulic oil flows out, prepare
an oil container.
2. Connection
1)Hold hose adapter (1) or hose (5) and insert it
in mating adapter (3), aligning them with
each other. (Fig. 4)
aDo not hold rubber cap portion (4).
2)After inserting the hose fitting in the adapter on
the other side perfectly, pull it back to check
the connecting condition (Fig. 5)
aWhen the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.
WA1200-6 00-27
Type 2 0 -2 8
1. Disconnection
1)Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2)While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3)While holding the condition of Steps 1) and 2),
pull out whole body (7) to disconnect it. (Fig.
8)
2. Connection
qHold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
00-28 WA1200-6
Type 3 0 -2 9
1. Disconnection
1)Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
2)While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3)While holding the condition of Steps 1) and 2),
pull out whole body (9) to disconnect it. (Fig.
12)
2. Connection
qHold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
WA1200-6 00-29
Handling of electric equipment
Handling of electric equipment 0 -30

(Rev. 2010/03)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at im-
proving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".
Points to remember when handling electric equipment 0 -30

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harnesses
1)Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about ten times.
2)Defective crimping or soldering of connectors
The pins of the male and female connectors
are attached to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.
00-30 WA1200-6
3)Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.
4)High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to spray water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5)Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it to dry with compressed air and spray it with
electric contact cleaner.
aWhen wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
aIf there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.
WA1200-6 00-31
3. Removing, installing, and drying connectors

and wiring harnesses
1)Disconnecting connectors
1]Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
aNever pull with one hand.
2]When removing from clips

qBoth of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.
qWhen removing a connector from a clip,

pull the connector in a parallel direc-
tion to the clip for removing stoppers.
aIf the connector is pried up and down or
to the left or right, the housing may
break.
3]Action to take after removing connectors

After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
aIf the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always
cover the connector.
00-32 WA1200-6
2)Connecting connectors
1]Check the connector visually.
Check that no oil, dirt, or water is stuck to
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
aIf there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
aIf there is any damage or breakage, re-
place the connector.
2]Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3]Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addi-
tion, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
aIf the connector cannot be corrected
easily, remove the clamp and adjust
the position.
qIf the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.
WA1200-6 00-33
3)Deutsch connector (DT 8-pin, 12-pin)

Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing locks (a) and (b), pull out the incomplete setting of
female connector (2). (a))
Connection (Right of figure)
1]Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2]Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
aRight of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
00-34 WA1200-6
4)Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1]Disconnect the connector and wipe off the
water with a dry cloth.
aIf the connector is to be blown with dry
compressed air, there is the risk that
oil in the air may cause defective con-
tact, remove oil and water in the air
before starting air blow.
2]Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
aHot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.
3]Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity
test to check for any short circuits
between pins caused by water.
aAfter completely drying the connector,
blow it with electric contact cleaner
and reassemble.
WA1200-6 00-35
4. Handling of connectors used on engine

aMainly, following engines are object for following connectors.
q95E-5
q107E-1
q114E-3
q125E-5
q140E-5
q170E-5
q12V140E-3
1)Slide, lock type (FRAMATOME-3, FRAM- 2)Pull lock type (PACKARD-2)

ATOME-2) q95/107/114/125/140/170/12V140 Series
q95/107/114/125/140/170/12V140 Series qVarious temperature sensors
qVarious pressure sensors and NE speed Examples)
sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure sensor in intake Fuel temperature sensor: TFUEL
manifold: PIM (125/170/12V140 Oil temperature sensor: TOIL
series) Coolant temperature sensor: TWTR,
Oil pressure sensor: POIL etc.
(125/170/12V140 series)
Oil pressure switch (95/107/114 Disconnection
series) Disconnect the connector by pulling lock (B)
Ne speed sensor on flywheel housing: (on the wiring harness side) of connector (2)
NE (95/107/114/125/140/170/12V140 outward.
series)
Ambient pressure sensor: PAMB
(125/170/12V140 series)
Disconnection
1]Slide lock L1 to the right.
2]While pressing lock L2, pull out connector
(1) toward you.
aEven if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver
while pressing lock L2, and then pull
out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".
Connection
00-36 WA1200-6
3)Push lock type (1) While pressing up lock (C) of the connector
q95/107/114 series with flat-head screwdriver [1], pull out
Example) Fuel pressure sensor in connector (3) in the direction of the arrow.
common rail (BOSCH-03)
Disconnection
While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 series
Connection
4)Push lock type (2)

q107/114 series
Example) Intake air pressure/tempera-
ture sensor in intake manifold (SUMI-
q107 series TOMO-04)
Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.
aIf the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
Connection
WA1200-6 00-37
5)Push lock type (3) Example) Intake air pressure sensor in

q95/125/140/170/12V140 series intake manifold.
(CANNON-04): PIM, etc.
Disconnection
While pressing lock (E) of the connector, pull
out connector (5) in the direction of the arrow. Disconnection
Example) Fuel pressure sensor in common 1]Turn housing (H1) in the direction of the
rail: PFUEL etc. (AMP-3) arrow.
aWhen connector is unlocked, housing
(H1) becomes heavy to turn.
2]Pull out housing (H1) in the direction of the
arrow.
aHousing (H1) is left on the wiring har-
ness side.
Example) Injection pressure control valve of

fuel supply pump: PCV (SUMITOMO-2)
Connection
1]Insert the connector to the end, while
setting its groove.
2]Turn housing (H1) in the direction of the
arrow until it "clicks".
Examples) Speed sensor of fuel supply

pump: G (SUMITOMO-3)
aPull the connector straight up.
Connection
6)Turn-housing type (Round green
connector)
q140 series
00-38 WA1200-6
5. Handling controller
1)The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2)Do not place objects on top of the controller.
3)Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4)During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5)Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6)Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.
6. Points to remember when troubleshooting

electric circuits
1)Be sure to turn the power OFF before discon-
necting or connecting connectors.
2)Before performing troubleshooting, check all
the related connectors for loose connection.
aDisconnect and connect the related con-
nectors several times to check.
3)Be sure to connect any disconnected connec-
tors before going on to the next step.
aIf the power is turned ON with the connec-
tors still disconnected, unnecessary
warning will be displayed.
4)When performing troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
aIf there is any change, there may be defec-
tive contact in the circuit.
WA1200-6 00-39
How to read electric wire code
How to read electric wire code 0 -40

(Rev. 2010/03)
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Exam- AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
ple: of 0.85
Indicates color of wire by color code.

Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)
1. Type, symbol, and material

AV and AVS are different only in thickness and outside diameter of the cover. CAVS has a circular
compressed conductor. It differs from AV and AVS in the outside diameter and thickness of the cover. And
AEX is similar to AV in thickness and outside diameter of the cover but different from AV and AVS in mate-
rial of the cover.
(Table 1)
Tempera-
Type Symbol Material ture range Example of use
for use ( °C)
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above)
biles Insulator Soft polyvinyl chloride
Thin low-volt- Annealed copper for electric
Conductor
age wire for appliance General wiring
AVS -30 – +60
automobile (nominal No. 3 and below)
Insulator Soft polyvinyl chloride
(type 1)
Thin low-volt- Annealed copper for electric
Conductor
age wire for appliance For mid- to small-size excavators
CAVS
automobile (nominal No. 1.25 and below)
Insulator Soft polyvinyl chloride
(type 2)
Annealed copper for electric
Heat resistant Conductor General wiring in extremely cold
appliance
low-voltage wire AEX -50 – +110 weather district, wiring at high
Heat-resistant crosslinked
for automobiles Insulator ambient temperature place
polyethylene
00-40 WA1200-6
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –

Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of 7/Circular com- 11/Circular com- 16/Circular com-
strands/Diame- – – –
ter of strand pressed pressed pressed
tor – 0.56 – 0.88 – 1.29
(mm2)
d (approx.) – 0.9 – 1.1 – 1.4

Cover D
CAVS Standard – 1.6 – 1.8 – 2.1
"f" of nominal No. denotes "flexible".
WA1200-6 00-41
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is "Green" and marking is "White".
4. Types of circuits and color codes
(Table 4)
Type of wire AVS, AV, CAVS AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of cir-
Br BrW BrR BrY BrB – – –
cuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
00-42 WA1200-6
Precautions when performing work
Precautions when performing work 0 -43

(Rev. 2010/03)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.
1. Precautions for removal work

qIf the coolant contains antifreeze, dispose of it correctly as chemicals.
qAfter disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
qWhen draining oil, prepare a container of adequate size to catch the oil.
qCheck the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
qTo prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
qAttach the tags to wires and hoses to show their installation position to prevent any mistake when install-
ing.
qCheck the number and thickness of the shims, and keep them in a safe place.
qWhen slinging component, be sure to use lifting equipment of ample strength.
qWhen using forcing screws to remove any component, tighten the forcing screws uniformly and alternate-
ly.
qBefore removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from en-
tering after removal.
aPrecautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly operations.
1)Face seal type hoses and tubes
Nominal Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 20210
03 07376 - 70315 02789 - 20315
04 07376 - 70422 02789 - 20422
05 07376 - 70522 02789 - 20522
06 07376 - 70628 02789 - 20628
10 07376 - 71034 07221 - 21034
12 07376 - 71234 07221 - 21234
2)Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500
3)If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 27 22.5 34
WA1200-6 00-43
2. Precautions for installation work

qTighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
qInstall the hoses without twisting or interference and fix them with intermediate clamps, if available.
qReplace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
qBend the cotter pins and lock plates securely.
qWhen coating with adhesive, clean and degrease the part, and coat the threaded portion with two to three
drops of adhesive.
qWhen coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making sure
that the surface is free from dirt or damage.
qClean all of the parts, and correct any damage, dents, burrs, or rust found on them.
qCoat the rotating parts and sliding parts with engine oil.
qWhen press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
qAfter installing the snap rings, check that the snap ring is settled in the ring groove completely.
qWhen connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
qWhen using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
qWhen installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on
one side.
aWhen operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic
pumps and other hydraulic component removed for repair, be sure to bleed the air as follows:
1]Start and run the engine at low idle.
2]Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stopping
the piston at 100 mm off the end of its stroke.
3]Next, operate the hydraulic cylinder three to four times to the end of its stroke.
aWhen using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions for completing work

1)Refilling of coolant, oil and grease
qIf the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system . Then add the coolant again if necessary.
qIf the hydraulic component is removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then add the oil again if necessary.
qIf the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system after
reassembling the parts, by referring to "Testing and adjusting".
qSupply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2)Check of installed condition of cylinder head and manifolds

Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any part is loosened, retighten it.
qFor the tightening torques, see the "Disassembly and assembly".
3)Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
00-44 WA1200-6
4)Checking muffler, exhaust pipe and their mounts for damage and looseness
1]Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2]Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5)Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
WA1200-6 00-45
Standard tightening torque table
Standard tightening torque table 0 -46

(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
aUnless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.
1)The following table applies to the bolts in Fig. A.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10(10) 11.8 – 14.7 1.2 – 1.5
8 13(12) 27 – 34 2.8 – 3.5
10 17(14) 59 – 74 6.0 – 7.5
12 19(17) 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
aValues with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2)The following table applies to the bolts in Fig. B.

Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
Fig. A Fig. B
aValues with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.
00-46 WA1200-6
2. Table of tightening torque for split flanged bolts

aUnless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
Tightening torque
eter of bolt flats
mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torque for O-ring boss piping joints

aUnless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table.
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
02 14 Varies 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
depending on
05, 06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of con-
10, 12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
nector.
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torque for O-ring boss plugs

aUnless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table.
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WA1200-6 00-47
5. Table of tightening torque for hoses (taper seal type and face seal type)
aUnless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
aApply the following torque when the threads are coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
number of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) (mm) threads, type of
erence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16-18UN 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torque for face seal joints

aTighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
aApply the following torque to the face seal joint while their threaded parts are coated with engine oil (wet-
ted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across Nominal No.
Thread diameter
eter of pipe flats –Number of
Range Target (mm)
(mm) (mm) threads, type of
(Reference)
thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UNS 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
00-48 WA1200-6
7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
aUnless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine se-
ries to the torque shown in the following table.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
aUnless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series to
the torque shown in the following table.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
aUnless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
WA1200-6 00-49
List of abbreviation
List of abbreviation 0 -50

(Rev. 2010/03)
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations that appear infrequently are marked in the text with an *.
q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual
Purpose of use (major appli-
Abbrevia-
Full Spelling cable machine (*), or compo- Explanation
tion
nent/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idle speed.
System
Instead of a steering wheel, a lever is used to per-
Advanced Joystick Steer- Steering
A.J.S.S. form the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is traveling downhill, if the
Automatic Retarder Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
Accelerator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is traveling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Speed Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-center Load
C.L.S.S. Hydraulic actuators regardless of the load (provides better
Sensing System
ease of combined operation than O.L.S.S.).
Uses engine controller to perform electronic control
of supply pump, common rail, and injector. Func-
C.R.I. Common Rail Injection Engine
tions to maintain optimum fuel injection amount
and fuel injection timing.
Electronic control device that uses the signals from
Electronic Control Mod-
E.C.M. Electronic control system the sensors on the machine to indicate to the actu-
ule
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electric Control Modula- Transmission
E.C.M.V. increases oil pressure to engage clutch and
tion Valve (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA)
absorb vibration of machine during travel
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
Exhaust Gas Recircula-
E.G.R. Engine bustion chamber in order to reduce combustion
tion
temperature, controls emission of Nox.
00-50 WA1200-6

Abbrevia-
tion
nent/system)
System that allows data (filter, oil replacement
Equipment Management interval, malfunctions on machine, failure code,
E.M.M.S. Machine monitor
Monitoring System and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in propor-
Electromagnetic Propor-
E.P.C. Hydraulic tion to the amperage of an electric current passing
tional Control
through the solenoid.
F-N-R Forward-Neutral-Reverse Operation Position of the gear shift lever or switch.
System that is used to determine the current loca-
Global Positioning Sys- Communication tion on the Earth of a ship, car, machine, etc. by
G.P.S.
tem (KOMTRAX, VHMS) receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Sys- Steering hydraulic motor and bevel shaft to control differ-
H.S.S.
tem (D) ence in travel speed of right and left tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combi-
Hydro Static Transmis- Transmission
H.S.T. nation of hydraulic pump and hydraulic motor to
sion (D, WA)
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
I.M.A. Inlet Metering Actuator Engine intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
I.M.V. Inlet Metering Valve Engine intake amount in order to control fuel discharge
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
L.C.D. Liquid Crystal Display Machine monitor
pixels filled with liquid crystal.
Semiconductor element that emits light when the
L.E.D. Light Emitting Diode Electronic parts voltage is applied in forward direction, positive volt-
age to anode and negative voltage to cathode.
Function that senses differential pressure of pump
L.S. Load Sensing Hydraulic
and controls discharge amount according to load.
Service that allows transmission and reception of
Multimedia Messaging
M.M.S. Communication short messages consisting of characters or voice
Service
or images between cell phones.
Device actuated to open electric or hydraulic cir-
N.C. Normally Closed Electric and hydraulic
cuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic cir-
N.O. Normally Open Electric and hydraulic
cuits that are normally open if not actuated.
Open-center Load Sens- Hydraulic system that can operate multiple actua-
O.L.S.S. Hydraulic
ing System tors at the same time, regardless of the load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
System in which a controller instantly analyses
Palm Command Control Steering data from each lever, pedal, and dial, and performs
P.C.C.S.
System (D) optimum electronic control of the engine and trans-
mission.
P.C.V. Pump Control Valve Engine intake amount in order to control fuel discharge
amount of supply pump.
Proportional Pressure Control system that moves an actuator in propor-
P.P.C. Hydraulic
Control tion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(D, PC, etc.)
P.T.O. Power Take Off Power transmission A device to take off power of the engine.
Power Tilt and power Work equipment Function that performs hydraulic control of the tilt
P.T.P.
Pitch dozer (D) and pitch of the bulldozer blade.
WA1200-6 00-51

Abbrevia-
tion
nent/system)
International System of Units (abbreviated SI from
the French Le Systeme Internationale d’Unites) is
the modern form of the metric system, and is the
Le Systeme International world’s most widely used system of measurement.
S.I. Unit
d’ Unites There’re seven base units: meter (m), kilogram
(kg), second (s), ampere (A), kelvin (K), candela
(cd), and mole (mol). The derived units include
Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
SOL. Solenoid Electric
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel con-
Vehicle Health Monitoring
V.H.M.S. tion sumption, radiator coolant temperature, oil or filter
System
(D, HD, PC, WA : Large size) replacement interval, to make it possible to collect
and check this data from a distant place (Devel-
oped for use on large machines used in mines).
*: Code for machine family
D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader
00-52 WA1200-6
List of abbreviations used in the circuit diagrams

Abbreviation Full Spelling
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actruator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
SW Switch
T/C Torque Converter
T/M Transmission
WA1200-6 00-53
Conversion table
Conversion table 0 -54

(Rev. 2010/03)
Method of using the conversion table 0 -54
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1)Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2)Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3)Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
meters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1)The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2)Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3)The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-54 WA1200-6
Conversion table
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 52.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA1200-6 00-55
Conversion table
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-56 WA1200-6
Conversion table
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA1200-6 00-57
Conversion table
Temperature 0 -5 8
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-58 WA1200-6
SEN0547504-00 01-
WA1200-6
WHEEL LOADER
Shop Manual 0-1
WA1200-6

WA1200-6 60001 and up
01 Specification 01-
WA1200-6 01-1
Contents
Contents 01-2
01 Specification
Specification............................................................................................................................ 01- 3
Specification dimension drawing.......................................................................................... 01- 3
Specifications....................................................................................................................... 01- 4
Weight table ......................................................................................................................... 01- 7
Table of fuel, coolant and lubricants .................................................................................... 01- 9
01-2 WA1200-6
Specification
Specification dimension drawing
Specification 01-3
Specification dimension drawing 01-3
Dimensions in ( ) are for the machine
equipped with 65/65-57-62PR tires.
Dimensions marked with* and ** are for ma-
chines equipped with a rock bucket and lime-
stone bucket respectively.
WA1200-6 01-3
Specification
Specifications
Specifications 01-4
Machine model WA1200-6
Serial number 60001 and up
Operating weight kg 216,400 [221,440]
Weight
Load on front axle kg 128,900 [131,900]

Load on rear axle kg 87,500 [89,540]
Bucket capacity (heaped) m3 20.0
Operating load kg 36,000
Travel speed forward 1st km/h 6.1 [6.0]
Travel speed forward 2nd km/h 11.1 [10.9]
Travel speed forward 3rd km/h 18.7 [18.3]
Performance
Travel speed reverse 1st km/h 6.3 [6.2]

Travel speed reverse 2nd km/h 11.4 [11.2]
Travel speed reverse 3rd km/h 19.3 [18.9]
Maximum rim pull kN {kg} 992 {101,200} [1,015 {103,480}]
Gradeability degree 25
Center of outside tire mm 12,015
Min. turning radius Outside of chassis
mm 14,330
(bucket with teeth)
Overall length (bucket with teeth) mm 18,310 [18,345]
Overall width (chassis) mm 5,820 [5,970]
6,400 (including cutting edges),
Bucket width mm
6,550 (including tire guards)
Overall height (to top of ROPS) mm 6,970 [6,930]
Overall height (with bucket fully raised) mm 12,205 [12,165]
Wheelbase mm 7,100
Dimension
Tread mm 4,300
Min. ground clearance mm 760 [715]
Maximum bucket hinge pin height mm 8,850 [8,810]
Dumping clearance (cutting edge end) mm 6,755 [6,725]
Dumping reach (cutting edge end) mm 2,585 [2,690]
Bucket tilt-forward angle degree 50.5 (with bucket fully raised)
Bucket tilt-back angle degree 50
Digging depth measured at cutting edge (with
mm 590 [630]
bucket 10 degree forward-tilt)
Dimensions in [ ] are for the machine equipped with
65/65-57-62PR tires.
01-4 WA1200-6
Specification
Specifications

Wet, multiple disc type brakes acting on front and
Foot brake
rear wheels independently, hydraulically actuated
Brake
Wet, multiple disc type brake acting on drive shaft

Hand brake (transmission output shaft), hydraulically released
and spring applied
Type Frame articulate steering
Steering
system
Structure Full hydraulic power steering
Quadruple type pump

q Torque converter and transmis-
l/min 752 (Gear pump: SAR (4) 200 + 200)
sion pump
q Brake cooling pump l/min 135 (gear pump: SAR (3) 71)
q Brake pump l/min 74.4 (gear pump: SAR (2) 40)
633 (variable displacement piston pump: HPV160
Work equipment pump (1) l/min
+ 160)
385 (variable displacement piston pump HPV95 +
Work equipment pump (2) l/min
Hydraulic 95)
pump q Cooling fan pump l/min 74.4 (gear pump: SAL (2) 40)
delivery
Switching pump l/min
+ 160)
q Hydraulic cooling pump l/min 418 (gear pump: SAR (3) 125 + 100)
Steering pump l/min
+ 160)
l/min
Hydraulic system
q Hydraulic control pump 135 (gear pump: SAR (2) 71)

q PPC pump l/min 126 (gear pump: SAR (2) 63)
Emergency steering pump l/min 352 (gear pump: SAM (3) 100 + 100)
Hydraulic
Cooling fan motor Fixed displacement piston motor: LMF40
motor
MPa
Transmission valve 2.65 {27} (spool type, electrically controlled)
{kg/cm2}
MPa
Control Steering valve 31.4 {320} (spool type)
{kg/cm2}
valve
MPa
set pressure EPC valve 3.9 {40} (electromagnetic type)
{kg/cm2}
MPa
Work equipment valve 31.4 {320} (2-spool type)
{kg/cm2}
Steering cylinder
number of cylinders - bore mm Double-acting piston type 2 - 225 x 660
x stroke
Lift arm cylinder
Cylinder number of cylinders - bore mm Double-acting piston type 2 - 360 x 1,835
x stroke
Bucket cylinder
number of cylinders - bore mm Double-acting piston type 2 - 300 x 985
x stroke
Work equipment
Type of link Z bar with duplex linkage
Shape of bucket cutting edge Spade nose with tip teeth
WA1200-6 01-5
Specification
Specifications

Description SSDA16V160E-2
4-cycle, water-cooled, V-type 16-cylinder,
Type
direct injection, with turbocharger and aftercooler
Number of cylinders - bore x stroke mm 16 - 159 x 190
Piston displacement (total piston displace-
l {cc} 60 {60,360}
ment)
Gross [SAE J1995] kW{HP}/rpm 1,411 {1,892}/1,800

Hosepower
ISO 14396 kW{HP}/rpm 1,411 {1,892}/1,800

Engine
Net [ISO 9249/SAE J1349] kW {HP}/rpm 1,316 {1,765}/1,800
Nm/rpm
Maximum torque 8,150/1,500 {831/1,500}
{kgm/rpm}
g/kW·h
Fuel consumption ratio 208 {153} (at rated horsepower: gross)
{g/PS·h}
Max. speed with no load rpm 1,900
Min. speed with no load rpm 650
Starting motor 24 V, 9.0 kW x 2
Alternator 24 V, 140 A
Battery 12 V, 160 Ah x 6
Torque converter 3-element, 1-stage, 1-phase (TCA51-3)
Planetary gear type, 3-forward and 3-reverse
Transmission
Power train
speeds
Reduction gear unit Spiral bevel gear type
Differential Straight bevel gear type
Final reduction gear Planetary gear, double reduction, oil bath lubrication
Drive method Front and rear wheel drive
Front axle Full floating type, fixed to frame
Rear axle Full floating type, supported by center pin
Tire (standard) 60/80-R57 (L5)
Axle and wheel
Tire (optional) 65/65-57-62PR (L5)

Tire (optional) 58/85-57-84PR (L5)
Wheel rim (60/80 tire) (standard)
Wheel rim (65/65 tire) (optional) 52.00 x 57/6.0
Wheel rim (58/85 tire) (optional)
kPa
Inflation pressure (front wheel) 690 {7.0}
{kg/cm2}
kPa
Inflation pressure (rear wheel) 590 {6.0}
{kg/cm2}
01-6 WA1200-6
(03)
Specification
Weight table
Weight table 01-7

Unit: kg
Engine 8,570
Radiator (including hydraulic oil cooler) 2,776
Cooling fan motor 13.9
Torque converter oil cooler 209
Torque converter 1,456
Transmission 3,781
Damper 375
Upper drive shaft 112
Center drive shaft 186
Front drive shaft 275
Rear drive shaft 287
Center support 164
Front axle 16,248
Rear axle 16,590
Front differential 1,618
Rear differential 1,843
Planetary carrier (per carrier) 880
Wheel hub (per hub) 710
Axle pivot (rear axle) (front/rear) 625/960
Tire (60 tire) (standard) (per tire) 5,894
Tire (65 tire/58 tire) (optional) (per tire) 7,100/6,033
Wheel (60 tire) (standard) (per wheel) 1,895
Wheel (65 tire/58 tire) (optional) (per wheel) 2,050/1,963
Steering valve 66
Steering cylinder (per cylinder) 584
Hydraulic tank (tank alone) 1,459 (1,248)
Work equipment pump (pump 1/ pump 2) 193/180
Torque converter pump + transmission pump + brake cooling pump +
72.8
brake pump
Switching pump + hydraulic cooling pump 237
Steering pump + control pump + PPC pump 221
Work equipment control valve (per valve) 95
Lift arm cylinder (each) 2,963
Bucket cylinder 1,399
Fender (one side) 135
Radiator guard 850
Front frame 15,750
Rear frame 18,480
WA1200-6 01-7
Specification
Weight table
Unit: kg
Bucket linkage (including bushing) (per linkage) 699
Bell crank (including bushing) (per bell crank) 2,454
Lift arm (including bushing) 18,240
Bucket (with teeth) 22,785
Rear bumper (including fuel tank) 6,820
Fuel tank (side tank x 2, center tank x 1) Side tank: 485 x 2, center tank: 622
Battery (per battery) 64
Cab assembly 588
Air conditioner unit 11
Operator's seat 50
Floor board 235
ROPS support assembly 3,155
01-8 WA1200-6
Specification
Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 01-9
WA1200-6 01-9
Specification
Table of fuel, coolant and lubricants
Reservoir Transmission Hydraulic oil Brake oil tank

Engine oil pan
Capacity case system Brake Cooling
Specified Liters 300 370 2000 90 300
capacity US gal 79.26 97.75 528.40 23.78 79.26
Liters 280 300 1360 75 290
Refill capacity
US gal 73.98 79.26 359.31 19.82 76.62
Axle
Reservoir Auto greasing Work equip-
(both of front and Cooling system Fuel tank
Capacity system ment pin
rear axles)
Specified Liters 670 – – 580 5100
capacity US gal 177.01 – – 153.24 1347.42
Liters 670 – – 570 –
Refill capacity
US gal 177.01 – – 150.59 –
Important
Always use diesel fuel. Never use any other fuel.
The engine on this machine uses electronic control and high-pressure fuel injection equipment to en-
able it to provide good fuel consumption and good exhaust gas characteristics. For this reason,
high-precision parts and lubricating ability are demanded. Using low-viscosity fuel with poor lubricat-
ing ability such as kerosene will cause a marked reduction in the durability of the engine.
Note 1: The power train oil and engine oil are different from each other. Use oils recommended for them re-
spectively.
Note 2: When using the machine equipped with the auto-greasing unit at temperatures below -20 °C, use Lith-
ium Grease No.0.
Note 3: Use GL-5 for the gear oil of SAE80W-90. Do not use GL-4.
Note 4: Coolant
1. Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well
as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze COOLANT
is essential.
Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has
excellent anticorrosion, antifreeze and cooling properties and can be used continuously for two years or
4000 hours.
SUPERCOOLANT (AF-NAC) is strongly recommended wherever available.
2. For details of the coolant density, see the following table.
Never dilute the COOLANT with ordinary water when using the diluted coolant.
Proportion table of water, coolant and additive
Minimum Temp °C -10 -15 -20 -25 -30
Amount of Liters 165 198 226 253 275
SUPERCOOLANT
US gal 43.59 52.31 59.57 66.84 72.65
(AF-NAC)
Liters 385 352 325 297 275
Amount of water
US gal 101.71 92.99 85.72 78.46 72.65
Amount of additive Liters 20
(DCA4) US gal 5.28
Volume ratio % 30 36 41 46 50
3. To maintain the anticorrosion properties of COOLANT, always keep the density of COOLANT between
30 % and 68 %.
01-10 WA1200-6
SEN0547506-00 10-1
WA1200-6
WHEEL LOADER
Shop Manual 1-01
WA1200-6

WA1200-6 60001 and up
10 Structure and function 10-1
WA1200-6 10-1
Contents
Contents 10-2
10 Structure and function
Damper ................................................................................................................................ 10- 4
Cooling system .................................................................................................................... 10- 5
Power train.............................................................................................................................. 10- 11
Power train........................................................................................................................... 10- 11
Hydraulic piping drawing of torque converter and transmission .......................................... 10- 13
Main relief valve and torque converter relief valve............................................................... 10- 24
ECMV................................................................................................................................... 10- 29
Transmission........................................................................................................................ 10- 35
Transmission lubricating oil relief valve ............................................................................... 10- 56
Transfer................................................................................................................................ 10- 57
Torque converter oil cooler .................................................................................................. 10- 59
Center support ..................................................................................................................... 10- 60
Axle ...................................................................................................................................... 10- 61
Final drive ............................................................................................................................ 10- 66
Steering system ...................................................................................................................... 10- 67
Steering equipment layout drawing...................................................................................... 10- 67
AJSS .................................................................................................................................... 10- 68
Steering pump...................................................................................................................... 10- 70
Switch pump ........................................................................................................................ 10- 72
Rotary valve ......................................................................................................................... 10- 99
EPC valve (for steering)....................................................................................................... 10- 102
Diverter valve ....................................................................................................................... 10- 103
Emergency steering relief valve........................................................................................... 10- 106
Steering lock valve............................................................................................................... 10- 107
Brake system .......................................................................................................................... 10- 108
Brake equipment layout drawing.......................................................................................... 10- 108
Brake valve .......................................................................................................................... 10- 109
Charge valve........................................................................................................................ 10- 115
Accumulator (for brake) ....................................................................................................... 10- 119
Slack adjuster ...................................................................................................................... 10- 120
Brake.................................................................................................................................... 10- 122
Parking brake....................................................................................................................... 10- 123
Parking brake solenoid valve ............................................................................................... 10- 124
Emergency parking brake release valve.............................................................................. 10- 125
Check valve of parking brake circuit .................................................................................... 10- 126
Axle mount ........................................................................................................................... 10- 129
Center hinge pin................................................................................................................... 10- 131
Jack-up point........................................................................................................................ 10- 132
Hydraulic piping layout drawing ........................................................................................... 10- 133
Work equipment control lever linkage.................................................................................. 10- 135
Hydraulic tank ...................................................................................................................... 10- 136
10-2 WA1200-6
Contents

EPC valve (for work equipment) .......................................................................................... 10- 175
Neutral cutoff solenoid valve (NC valve).............................................................................. 10- 177
Relief valve .......................................................................................................................... 10- 179
Accumulator (for EPC valve) ............................................................................................... 10- 180
Work equipment...................................................................................................................... 10- 194
Machine monitor system...................................................................................................... 10- 196
Multi-function monitor .......................................................................................................... 10- 224
Work equipment and AJSS control system ......................................................................... 10- 277
Transmission control system ............................................................................................... 10- 315
Engine starting circuit .......................................................................................................... 10- 341
Engine stopping circuit......................................................................................................... 10- 343
Electric parking brake control .............................................................................................. 10- 347
Sensor ................................................................................................................................. 10- 357
WA1200-6 10-3
Engine and cooling system
Damper
Engine and cooling system 10-4

Damper 10-4
1. Shaft Function 10-4

2. Breather q The damper is to relieve the torsional vibration
3. Rubber cushion due to the engine's torque change and protect
4. Inner body driving system after engine from the torsional vi-
5. Rubber cushion bration.
6. Outer body
Operation 10-4
q The engine's power is transmitted from flywheel
to outer body (6), and the rubber cushions (3)
and (5) absorb the engine's torsional vibration.
The power is further transmitted through inner
body (4) and shaft (1) to the upper drive shaft be-
tween the damper and the torque converter.
10-4 WA1200-6
Cooling system
Cooling system 10-5
1. Fan guard Radiator specifications 10-5

2. Coolant level sensor port LTC HTC
3. Water port
4. Sub-tank Core type Modular core Modular core
5. Upper tank Total heat dissipa-
211.6 398.2
6. Hydraulic oil cooler tion area(m2)
7. Radiator (LTC) Water passage
59,042 88,690
8. Radiator (HTC) area(cm2)
9. Lower tank *LTC: Low Temperature Coolant
*HTC: High Temperature Coolant
WA1200-6 10-5
Cooling fan motor
Cooling fan motor 10-6

Type: LMF40
P: From fan pump

T: To tank from cooler
TC: To tank
Specifications 10-6
Type: LMF40
Capacity: 40 cc/rev
Rated speed: 1,900 rpm
Rated flow rate:76.0 l/min
Check valve crack pressure: 49 kPa {0.5 kg/cm2}
10-6 WA1200-6
Cooling fan motor
1. Output shaft 6. Valve plate

2. Case 7. End cover
3. Thrust plate 8. Center spring
4. Piston assembly 9. Check valve
5. Cylinder block 10. Safety valve
WA1200-6 10-7
Cooling fan motor
Hydraulic motor 10-8
Function 10-8
q This hydraulic motor is called a swash plate axial
piston motor. It converts the energy of the pres-
surized oil sent from the hydraulic pump into ro-
tary motion.
Principle of operation 10-8

q The pressurized oil sent from the pump flows
through valve plate (7) to cylinder block (5).
q The pressurized oil is to flow only to single side
of (Y-Y) connecting top and bottom dead centers
in the stroke of piston (4).
q The pressurized oil entered into the one side of
q This resultant force [T=s(F3xri)] of torques, as a
cylinder block (5) pushes each piston (4) (two or turning force, rotates cylinder block (5) through
three pistons). piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.
q The force generated per piston: F1 (kg) = P

(kg/cm2) x x D2 / 4 (cm2).
q This force acts on thrust plate (2).
q AS thrust plate (2) is fixed to output shaft (1) at a
certain angle (a), the force is divided into compo-
nent forces (F2) and (F3).
q Radial component forces (F3) of these compo-

nent forces generates torque (T=F3 x ri) each on
(Y-Y) connecting top and bottom dead centers.
10-8 WA1200-6
Cooling fan motor
Suction valve 10-9
Function 10-9 2) When stopped 10-9

q When the pump stops rotating, the pressurised q When the engine stops, the pump speed be-
oil does not flow into the motor. comes 0 rpm.
q Since the motor continues to rotate with the force q The pressurized oil from the pump is not sup-
of inertia the pressure on the outlet side of the plied to port (P).
motor rises. q Since the pressurized oil is not supplied to (MA)
q When the pressurized oil flow stops from inlet side of the motor, the motor speed decreases
port (P), suction valve (1) sucks in the pressur- gradually to stop.
ized oil on the outlet side and supplies it to port q If the motor shaft rotates with the inertia force
(MA) where there is not sufficient oil to prevent while the pressurized oil flow to port (P) reduces,
the occurrence of cavitation. the pressurized oil in port (T) on the outlet side is
sent by suction valve (1) to MA side to prevent
Operation 10-9 cavitation.
1) When pump is started 10-9

q The pressurized oil from the pump is supplied to
port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor and
the motor starts rotating.
q The pressurized oil on the motor outlet (MB) side
returns through port (T) to the tank.
WA1200-6 10-9
Cooling fan motor
Safety valve 10-10
Function 10-10
q When the engine is started, the pressure in port
(P) of the fan motor is increased in some cases.
q Safety valve (1) is installed in order to protect the
fan system circuit.
Operation 10-10
q When the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2) of
safety valve (1) opens and release the pressur-
ized oil to port (T).
q By this operation, the generation of the unusual
high-pressure in port (P) is prevented.
10-10
10-10 WA1200-6
Power train
Power train
Power train 10-1

Power train 10-1
Outline 10-1 1. Front differential

q The power of engine (16) is transmitted through 2. Front brake
engine's flywheel to damper (15). The output 3. Front final drive
shaft of damper (15) is connected through upper 4. Front tire
drive shaft (14) to modulation clutch (13). The 5. Front axle
modulation clutch output is connected to the 6. Front drive shaft
pump of torque converter (11). The torque con- 7. Center drive shaft
verter turbine is connected to the input shaft of 8. Emergency steering pump
transmission (10). 9. Transfer (output)
q The transmission has five hydraulically-actuated 10. Transmission
clutches and provides three stages of speed for 11. Torque converter
moving forward and reverse respectively, and 12. Transfer (input)
the speed is selected with electrically controlled 13. Modulation clutch
switch. 14. Upper drive shaft
q The output shaft of the transmission is connect- 15. Damper
ed to the gear of transfer (9) and the power is 16. Engine
transmitted to the output shaft. The power is 17. Work equipment pump No.1
transmitted from the transfer output shaft 18. Work equipment pump No.2
through center drive shaft (7), center support 19. Cooling fan pump
(34), front drive shaft (6), and rear drive shaft 20. Switch pump
(33) to front axle (5) and rear axle (30), and fur- 21. Hydraulic cooling pump
ther is transmitted through wheel to tires. 22. Steering pump
23. Control pump
24. PPC pump
WA1200-6 10-11
Power train
Power train
25. Torque converter, transmission pump 31. Rear differential

26. Brake cooling pump 32. Rear brake
27. Brake pump 33. Rear drive shaft
28. Rear final drive 34. Center support
29. Rear tire 35. Parking brake
30. Rear axle
10-12 WA1200-6
Power train
Hydraulic piping drawing of torque converter and transmission
Hydraulic piping drawing of torque converter and transmission 10-13
1. Transmission
2. Transmission valve
3. Transfer (input)
4. Torque converter oil cooler
5. Torque converter charging pump
6. Torque converter
7. Oil filter
8. Transmission oil level gauge
9. Transfer (output)
WA1200-6 10-13
Power train
Hydraulic piping drawing of torque converter and transmission
10-14 WA1200-6
Power train
Torque converter
Torque converter 10-15

(input transfer, PTO, modulation clutch, torque converter)
WA1200-6 10-15
Power train
Torque converter
A: To oil cooler 1. Mounting location of steering pump, control

B: Torque converter outlet port pump, and PPC pump
C: Oil pressure pickup port of torque converter outlet 2. Switch pump and hydraulic oil cooling pump
D: To main relief valve mounting location
E: PTO, input transfer, modulation clutch lubrication 3. Mounting location of transmission charging
port pump, torque converter charging pump, brake
F: Interconnection port cooling pump, and brake pump
G: From transmission pump 4. Regulator valve of torque converter outlet
H: Modulation clutch oil pressure pickup port 5. Work equipment pump mounting location
J: Oil pressure pickup port of torque converter inlet 6. Work equipment pump and cooling fan pump
K: Main relief pressure pickup port mounting location
L: Drain port 7. Modulation clutch output shaft speed sensor
8. ECMV for modulation clutch
9. Main relief, torque converter valve
10. Input speed sensor of input transfer
10-16 WA1200-6
Power train
Torque converter
WA1200-6 10-17
Power train
Torque converter
11. Coupling 21. Torque converter input shaft

12. Drive gear (number of teeth: 74) 22. Drive case
13. PTO gear (number of teeth: 68) 23. Turbine
14. PTO gear (number of teeth: 68) 24. Stator
15. Idler gear (number of teeth: 68) 25. Pump
16. Modulation clutch output shaft 26. Torque converter case
17. Modulation clutch piston 27. Transmission input shaft
18. Modulation clutch outer drum 28. Driven gear (number of teeth: 58)
19. Modulation clutch inner drum 29. Modulation clutch disc
20. Coupling 30. Modulation clutch plate
10-18 WA1200-6
Power train
Torque converter
Specifications 10-19
Model: 42C-13-21000
Type: 3-element, 1-stage, 1-phase
Stall torque ratio: 2.23 (T3/T1)
2.84(T3/T2)
WA1200-6 10-19
Power train
Torque converter
Operation 10-20
Power transmitting route 10-20
10-20 WA1200-6
Power train
Torque converter
q The torque converter is installed between a damper

and a transmission, and the power is transmitted as fol-
(from lower left)
lows:
Engine power O
O Modulation clutch output shaft (16)
Damper O
O Coupling (20)
Universal joint O
O Torque converter input shaft (21)
Coupling (11) O
O Drive case (22) and pump (25) rotate together
Drive gear (12) O
O Oil is used as medium
Idler gear (15) O
O Turbine (23)
Driven gear (28) O
O Transmission input shaft (27)
Modulation clutch inner drum (19)
O q The power transferred to coupling (11) is transmitted
Modulation clutch disc (29), plate (30) through drive gear (12), PTO gear (13), and idler
O gear (15) to the pump as a driving power.
Modulation clutch outer drum (18)
O
(to upper right)
WA1200-6 10-21
Power train
Torque converter
Flow of oil
q The oil which goes through the main relief valve

and whose pressure is adjusted to the set pres-
sure by the torque converter relief valve flows in
inlet port A, merges the oil flowed from torque
converter charging pump in the path of torque
converter case (26), and flows to pump (25).
Set pressure: 1.10 MPa {11.2 kg/cm2}
Pump (25) applies centrifugal force to the oil,
and the oil enters into turbine (23) and transmits
energy to turbine (23).
The oil is sent from turbine (23) to stator (24) and
is put into pump (25) again. A part of the oil is
sent from stator (24) through outlet port B to the
outlet regulator valve of the torque converter.
The oil sent to the outlet regulator valve of the
torque converter goes through the oil cooler for
cooling and is used for lubricating the transmis-
sion.
10-22 WA1200-6
Power train
Torque converter
Modulation clutch 10-23

Outline 10-23 Operation 10-23
q The modulation clutch is installed between the Complete engagement: 10-23
input transfer and the torque converter. q The oil sent from ECMV (1) for modulation clutch
q It is enabled to change the clutch from complete flows through the oil path of modulation clutch
engagement to slippage by adjusting the clutch case (2) to piston (3) and moves piston (3) right-
oil pressure by using ECMV. ward.
q The slipping clutch can reduce the power trans- When piston (3) operates and clutch oil pressure
mitted to the torque converter. increases, the pressing force of piston (3)
increases, and disc (4) and plate (5) contacts
closely and inner drum (6) and outer drum (7)
are engaged.
Thus, the power transferred from inner drum (6)
is transmitted 100% to outer drum (7).
Slippage: 10-23
q When the signal to reduce the clutch oil pressure
is issued by the controller, the clutch oil pressure
is reduced by using ECMV (1) for modulation
clutch.
When the clutch oil pressure is reduced, the
pressing force of piston (3) decreases, a slip-
page occurs between disc (4) and plate (5), and
outer drum (7) rotates slower than inner drum
(6).
In consequence, the power transmitted is
reduced.
q The power transmitted is determined by the slip-

page rate of the clutch and the speed ratio of the
torque converter.
Slippage rate = (1 - output rotation/input rotation)
x 100 (%)
1. ECMV for modulation clutch

2. Modulation clutch case
3. Piston
4. Disc
5. Plate
6. Inner drum
7. Outer drum
WA1200-6 10-23
Power train
Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve 10-24
A: From pump 1. Valve body

B: To torque converter 2. Valve spring (small)
C: To transmission lubrication circuit 3. Valve spring (large)
D: Drain 4. Main relief valve spool
E: Drain 5. Piston spring
F: Drain 6. Piston
G: Drain 7. Valve spring
P1: Oil pressure pickup port at torque converter inlet 8. Torque converter relief valve spool
P4: Main oil pressure pickup port 9. Piston spring
10. Piston
Outline 10-24
Main relief valve 10-24
q The main relief valve holds a transmission oil
pressure in the set pressure.
Set pressure: 2.65 MPa {27 kg/cm2} (at rated
rotation of engine)
Torque converter relief valve 10-24

q The torque converter relief valve is attached to
the torque converter inlet circuit so that the oil
pressure of torque converter inlet circuit is al-
ways kept to the set pressure or lower in order to
protect the torque converter against unusual
high-pressure.
Set pressure : 1.10 MPa {11.2 kg/cm2} (cracking
pressure)
10-24 WA1200-6
Power train
Operation 10-25
Operation of main relief valve 10-25
q The oil from the torque converter charging pump q When the oil pressure increases, the oil in cham-
flows through the filter to port A in spool (4), and ber B pushes piston (6), and the reaction force
further flows through orifice a to port B. compresses valve springs (2) and (3) to move
When the oil from the pump is filled in the circuit, spool (4) leftward and open ports A and C.
the oil pressure starts to increase. Then, the oil from the pump relieves to port C
through port A and flows from port C into the
torque converter.
At this point, the oil pressure in port A is 2.65
MPa {27 kg/cm2} (at rated speed of engine).
WA1200-6 10-25
Power train
Operation of torque converter relief valve 10-26

q The oil which acted on the main relief valve flows
from port C into the torque converter, and at the
same time, flows through orifice b in spool (8) to
chamber D.
When the oil is filled in the torque converter, the
oil pressure starts to increasing.
q When the oil pressure increases, the oil in cham-
ber D pushes piston (10), and its reaction force
compresses valve springs (7) to move spool (8)
rightward and open ports C and E.
Then, the oil in port C flows in port E and flows
into the transmission lubricating circuit.
At this time, the oil pressure at port C is 1.10
MPa {11.2 kg/cm2} (cracking pressure).
10-26 WA1200-6
Power train
Torque converter regulator valve
Torque converter regulator valve 10-27
A: From torque converter 1. Valve body

B: To oil cooler 2. Valve spring (small)
3. Valve spring (large)
4. Spool
5. Piston spring
6. Piston
Outline 10-27
q In order for the torque converter to fully display
its performance, it is attached to the outlet port
circuit of the torque converter for adjusting the oil
pressure in the torque converter to the set pres-
sure.
Set pressure: 0.88 ± 0.10 MPa {9 ± 1 kg/cm2}
WA1200-6 10-27
Power train
Operation 10-28
q The oil from torque converter flows from port A
through orifice a to chamber B. But the force of
oil pressure in chamberB is lower than the ten-
sion of valve springs (2) and (3), so spool (4)
does not move.
q When the force of the oil pressure in chamber B

becomes larger than the tension of valve springs
(2) and (3), the oil entered into chamber B push-
es piston (6) and the reaction force compresses
valve springs (2) and (3) to move spool (4) left-
ward and ports A and C are opened.
10-28 WA1200-6
Power train
ECMV
ECMV 10-29
A: To clutch 1. Connector
B: Drain 2. Spring
C: From pump 3. Flow detection valve spool
P: Clutch pressure measuring port 4. Spring
5. Fill switch
6. Proportional solenoid
7. Pressure control valve spool
8. Load piston
9. Spring
WA1200-6 10-29
Power train
ECMV
Outline 10-30
Outline of ECMV 10-30 ECMV and proportional solenoid 10-30
q ECMV (Electronic Control Modulation Valve) is q Single proportional solenoid is installed to each
composed of two valves: pressure control valve ECMV.
and flow detection valve. The thrust is generated as shown in the figure
q Pressure control valve based on the command current from the
Valve, which converts the current which is sent controller.
from the controller and received by the propor- The thrust generated in the proportional solenoid
tional solenoid, into an oil pressure. is applied to the pressure control valve spool to
q Flow detection valve generate oil pressure as shown in the figure.
This valve is activated by a trigger from the pres- Thus, the thrust changes by controlling the
sure control valve and has the following func- command current to activate the pressure
tions: control valve and control the oil flow and oil pres-
1) Reduces the filling time of the clutch by sure.
opening the valve until the oil fills the clutch.
2) Closes the valve as soon as oil fills in the
clutch and outputs the signal (fill signal) to the
controller to inform of the end of filling.
3) When the clutch is applied oil pressure,
outputs the signal (fill signal) to the controller
to inform whether oil pressure is present.
A Range: before gear shift (draining)
B Range: filling start (triggering)
C Range: filling end
D Range: adjusting pressure
E Point: filling
ECMV and fill switch 10-30

q Single fill switch is installed to each ECMV.
When the clutch finishes filling, the fill switch is
turned ON by the flow detection valve. The oil
pressure starts build-up based on this signal.
10-30 WA1200-6
Power train
ECMV
Operation 10-31
Operation of ECMV 10-31 1. Before gear shift (draining) (range A in the
q ECMV is controlled by the command current diagram)
sent to proportional solenoid from the controller When the current does not flow in proportional
and the fill switch output signal. solenoid (6), the repulsive force of spring (9) for
The following figure shows the relation among the pressure control valve thrusts back propor-
the command current to proportional solenoid, tional solenoid (6) through pressure control
the clutch input pressure, and the fill switch valve spool (7), so pressure control valve spool
output signal. (7) drains the oil in clutch port C through drain
port E.
A Range: before gear shift (draining) At this time, as the oil pressure does not act on
B Range: filling start (triggering) flow detection valve spool (3), flow detection
C Range: filling end valve spool (3) is put away from fill switch (5) by
D Range: adjusting pressure the repulsive force of fill switch spring (4) and
E Point: filling stands still in the position where it balances with
return spring (2) of the flow detection valve.
WA1200-6 10-31
Power train
ECMV
2. When the filling starts (trigger command is input 2) At this time, the differential pressure is gener-
into the pressure control valve) (range B in the ated between upstream and downstream
diagram) sides of orifice a of flow detection valve spool
1) When the trigger current is applied (3).
(maximum current is applied) to proportional This differential pressure compresses return
solenoid (6) while no oil exists in the clutch, spring (2) for the flow detection valve and
proportional solenoid (6) moves to the stroke moves flow detection valve spool (3) left-
end to move pressure control valve spool (7) ward.
leftward. Then, flow detection valve spool (3) opens
This opens pump port A and pressure control pump port D and the oil flows through orifice
valve port B and starts to fill the clutch with oil a to clutch port C.
through orifice a of flow detection valve spool
(3).
10-32 WA1200-6
Power train
ECMV
3. When the filling ends (set the pressure control 2) When the clutch is filled with oil, the oil flow
valve to initial pressure) (range C in the diagram) from output port B of the pressure control
1) When pump port D of flow detection valve valve to clutch port C stops. As the left and
opens and the oil flows, the differential pres- right reception areas of flow detection valve
sure is generated between upstream and spool (3) are different from each other and
downstream sides of orifice a in flow detec- the left reception area is larger than the right
tion valve spool (3) to push flow detection one. When the oil pressures of both sides are
valve spool (3) leftward. equal to each other, flow detection valve
Then, when the current in proportional sole- spool (3) moves rightward with the oil pres-
noid (6) is reduced to instantaneous initial sure. Whereby, the pump port D and clutch
pressure level, almost of the pump pressure port C close. Then, flow detection valve spool
is applied to load piston (8), so pressure (3) compresses fill switch spring (4) because
control valve spool (7) is pushed back right- of the area difference between right and left
ward and a little amount of oil leaks out from sides and tension of back spring (2) of flow
pressure control valve port B to drain port E. detection valve, and moves rightward to
However, as the amount of this leakage is come into contact with fill switch (5) and it is
small, almost of oil from the pump flows into informed to the controller that the clutch
the clutch and flow detection valve spool (3) finished the filling. In this case, the current at
is pushed leftward. initial pressure level flows to proportional
solenoid (6) and the oil pressure of pressure
control valve spool (7) is set to an initial pres-
sure.
WA1200-6 10-33
Power train
ECMV
4. Adjusting pressure (range D in the diagram)

When the current flows in proportional solenoid
(6), the solenoid generates force in proportion to
the current. The pressure is adjusted by this
thrust of solenoid, the thrust from the oil pressure
of clutch port C applied to load piston (8), and the
repulsive force of pressure control valve spring
(9).
Flow detection valve spool (3) is pressed right-
ward by the difference between the oil pressures
applied on both sides to continue to output the fill
signal to the controller.
10-34 WA1200-6
Power train
Transmission
Transmission 10-35
(transmission, transfer, parking brake)
1. Transmission valve
2. Transmission input shaft
3. Transmission
4. Transfer
5. Output coupling (front)
6. Drain plug
7. Parking brake
8. Output coupling (rear)
9. Mounting port of travel speed sensor
10. Mounting port of oil filler port
11. Check-valve Ass'y in parking brake circuit
WA1200-6 10-35
Power train
Transmission
A: From oil filter K: From torque converter case drain

B: From oil cooler L: To modulation clutch (lubrication) and input
C: Lubricating oil pressure pickup port transfer (lubrication)
D: To parking brake M: From parking solenoid valve
E: To modulation clutch ECMV N: To transmission lubrication circuit
F: To torque converter P: To transmission lubrication circuit
G: From torque converter case (drain) Q: To 1st clutch
H: From torque converter case drain R: To 2nd clutch
J: Suction port S: To 3rd clutch
T: To forward clutch
U: To reverse clutch
10-36 WA1200-6
Power train
Transmission
WA1200-6 10-37
Power train
Transmission
1. Transmission input shaft

2. Pinion shaft
3. Clutch disc
4. Clutch plate
5. Planetary pinion No.1 (reverse) (number of teeth:
31)
6. Clutch housing No.1 (reverse)
7. Ring gear No.1 (reverse) (number of teeth: 88)
8. Clutch housing No.2 (forward)
9. Ring gear No.2 (forward) (number of teeth: 165,
94)
10. Planetary pinion No.2 (forward) (teeth: 28)
11. Pinion shaft
12. Planetary pinion No.3 (3rd) (number of teeth: 28)
13. Ring gear No.3 (3rd) (number of teeth: 165, 94)
14. Clutch housing No.3 (3rd)
15. Pinion shaft
16. Planetary pinion No.4 (2nd) (number of teeth:
22)
17. Clutch housing No.4 (2nd)
18. Ring gear No.4 (2nd) (number of teeth: 165, 94)
19. Piston return spring No.5 (1st)
20. Clutch piston No.5 (1st)
21. Rear housing
22. Transmission output shaft
23. Clutch housing No.5 (1st)
24. Carrier No.4 (2nd) (number of teeth: 94)
Clutch drum No.5 (1st) (number teeth: 164)
25. Clutch hub No.5 (1st)
26. Sun gear No.4 (2nd) (number of teeth: 50)
27. Clutch piston No.4 (2nd)
28. Piston return spring No.4 (2nd)
29. Sun gear No.3 (3rd) (number of teeth: 38)
30. Clutch piston No.3 (3rd)
31. Piston return spring No.3 (3rd)
32. Carriers No.2 and No.3 (forward, 3rd) (number
of teeth: 88)
33. Clutch piston No.2 (forward)
34. Sun gear No.2 (forward) (number of teeth: 38)
35. Piston return spring No.2 (forward)
36. Clutch piston No.1 (reverse)
37. Sun gear No.1 (reverse) (teeth: 26)
38. Ring gear No.1 (reverse) (teeth: 165, 94)
39. Carrier No.1 (reverse) (number of teeth: 94)
40. Piston return spring No.1 (reverse)
41. Pin
42. Washer spring
43. Tie bolt
44. Front housing
10-38 WA1200-6
Power train
Transmission
Outline 10-39 Operation 10-39

q The transmission is composed of the transmis- Operation of clutch 10-39
sion with "forward 3-speeds, reverse 3-speeds" q In order to lock ring gear (38), piston (36), plate
in combination with the planet gear mechanism (4), disc (3), pin (41), piston return spring (40),
and disc clutch, transfer, parking brake, and washer spring (42) are used.
transmission control valve. q The internal teeth of disc (3) are engaged with
q In the transmission single rotation direction and the outside teeth of ring gear (38).
speed are selected by operating two hydraulical- q The projection cut-out portion of plate (4) is en-
ly engaging clutches out of five pairs of planetary gaged with pin (41) fixed to clutch housing (6).
gear mechanism and disc clutch by using a con-
trol valve.
q Clutch No.1 is engaged for reverse, clutch No.2
for forward, clutch No.3 for 3rd speed, clutch
No.4 for 2nd speed, and clutch No.5 for 1st
speed.
Gear speeds and engaged clutches

Gear speed Clutch engaged
Forward 1st No.2, No.5
Forward 2nd No.2, No.4
Forward 3rd No.2, No.3
Reverse 1st No.1, No.5 Clutch engaged (fixed) 10-39
Reverse 2nd No.1, No.4 q The pressurized oil sent from transmission con-
trol valve is supplied through a path in the trans-
Reverse 3rd No.1, No.3
mission to the back of piston (36) to move piston
(36) leftward.
Number of plates and discs used q Piston (36) presses plate (4) and disc (3) to con-
Number of tact each other, and the frictional force stops

Clutch No. Number of plates disc's rotation and locks ring gear (38) engaged
discs
Clutch No.1 7 8 with the internal teeth of disc (3).
Clutch No.2 8 9
Clutch No.3 4 5
Clutch No.4 3 4
Clutch No.5 8 9
WA1200-6 10-39
Power train
Transmission
Clutch disengaged (released) 10-40

q When the oil sent from the transmission control
valve is shut off, piston return spring (40) puts
piston (36) back into place to release the friction-
al force between plate (4) and disc (3), and puts
ring gear (38) in neutral.
q Washer spring (42) is installed between plates
(4) in the pin part so that, when the clutch is re-
leased, piston (36) can return quickly, and at the
same time plate (4) and disc (3) can detach
themselves from each other quickly, to prevent
drag turning.
10-40 WA1200-6
Power train
Transmission

Forward 1st 10-41
q Forward ring gear (9) in the forward clutch and 1st clutch hub (25) are engaged by using oil pressure.
Power from torque converter
O
Input shaft (1)
O
F sun gear (34)
O
F Planetary pinion (10)
O
F, 3rd carrier (32)
O
3rd clutch planetary pinion (12) o 3rd sun gear (29)
O O
3rd clutch ring gear (13)
O O
2nd carrier, 1st clutch drum (24)
O O
1st clutch hub (25)
O
Output shaft (22) i i
WA1200-6 10-41
Power train
Transmission
Forward 2nd 10-42
q Forward ring gear (9) in the forward clutch and 2nd ring gear (18) are engaged by using oil pressure.
O
Input shaft (1)
O
F sun gear (34)
O
O
F, 3rd carrier (32)
O
O O
O O
O O
2nd Planetary pinion (16)
O O
2nd sun gear (26)
O
10-42 WA1200-6
Power train
Transmission
Forward 3rd 10-43
q Forward ring gear (9) in the forward clutch and 3rd ring gear (13) in the 3rd clutch are engaged by using
oil pressure.
O
Input shaft (1)
O
F sun gear (34)
O
O
F, 3rd carrier (32)
O
3rd clutch planetary pinion (12)
O
3rd sun gear (29)
O
Output shaft (22)
WA1200-6 10-43
Power train
Transmission
Reverse 1st 10-4
q Reverse ring gear (38) in the reverse clutch and 1st clutch hub (25) are engaged by using an oil pressure.
O
Input shaft (1)
O
R sun gear (37)
O
R Planetary pinion (5)
O
R ring gear (7)
O
F, 3rd carrier (32)
O
O O
O O
O O
1st clutch hub (25)
O
10-44 WA1200-6
Power train
Transmission
WA1200-6 10-45
Power train
Transmission control valve
Transmission control valve 10-46
10-46 WA1200-6
Power train
A: Pressure pickup port of reverse clutch

B: Pressure pickup port of forward clutch
C: Pressure pickup port of 3rd clutch
D: Pressure pickup port of 2nd clutch
E: Lubricating oil pressure pickup port
F: Pressure pickup port of 1st clutch
G: To parking brake valve
H: To modulation clutch ECMV
1. Bypass fill valve, bypass drain valve

(for reverse clutch)
2. ECMV (for reverse clutch)
3. Bypass fill valve (for forward clutch)
4. ECMV (for forward clutch)
5. Lubricating oil relief valve
6. Bypass fill valve (for first clutch)
7. ECMV (for 1st clutch)
8. ECMV (for 2nd clutch)
9. ECMV (for 3rd clutch)
10. Pilot filter
11. Check-valve Ass'y of parking brake circuit
Table of ECMV operation
Clutch
Gear speed
No.1 No.2 No.3 No.4 No.5
In automatic
Neu- Q
mode
tral
In manual
(N) Q Q Q
shift mode
Forward 1st (F1) Q Q
Forward 2nd (F2) Q Q
Forward 3rd (F3) Q Q
Reverse 1st (R1) Q Q
Reverse 2nd (R2) Q Q
Reverse 3rd (R3) Q Q
* In neutral manual position, the clutch is engaged
in the gear shift where the gear shift lever is lo-
cated.
WA1200-6 10-47
Power train
Bypass fill valve 10-48

Outline 10-48
q As for the clutch whose piston volume is large,
operating ECMV alone as usual takes some time
filling of oil and the filling time is prolonged, so
you may feel time lag at a speed change.
Therefore, as for the clutch whose piston volume
is large, a bypass fill valve is installed so that the
bypass fill valve is activated together with ECMV
to increase the filling flow rate at filling of oil.
* The bypass fill valves are installed in the reverse,
forward, and 1st clutch circuits
Relation between bypass fill valve and ECMV 10-48

q The bypass fill valve is controlled by the com-
mand current from the transmission control. The
diagram on the right shows the relation between
the fill valve and ECMV.
Range A: before gear shift (draining)
Range B: filling starts
(filling at a high rate by opening the
bypass fill valve and ECMV at the same
time)
Range C: filling
(filling at a medium rate by opening ECMV
only)
Range D: filling ends
(filling ends at a low rate of filling of oil by
opening ECMV only)
Range E: adjusting of pressure by using ECMV
Range F: filling
10-48 WA1200-6
Power train
Operation 10-49
When the solenoid valve is de-energized 10-49
q As spool (2) in solenoid valve (1) is pushed right-
ward by return spring (3), chamber A and port T
are open and there is no oil pressure in chamber
A.
Therefore, spool (4) in the bypass fill valve is
pushed rightward by return spring (5), and ports
P and C are closed.
When the solenoid valve is energized 10-49

q When current flows in solenoid valve (1), spool
(2) is pushed leftward, so port P and chamber A
open to supply the pressurized oil to chamber A.
Thus, spool (4) is moved leftward by the pressur-
ized oil, ports P and C are opened, and the oil
from the pump is supplied to the clutch.
WA1200-6 10-49
Power train
Bypass drain valve 10-50

Outline 10-50 When the solenoid valve is energized (discharg-
q When the clutch is disengaged, the oil in the ing clutch oil) 10-50
clutch piston is drained through ECMV into the q When current flows in solenoid valve (1), spool
transmission case. (2) is pushed leftward, so port P and chamber A
When the clutch's piston volume is large, if open and the pressurized oil is supplied to cham-
ECMV only is operated as usual, it takes some ber A.
time to discharge oil. When next gear shift starts Thus, spool (4) is moved leftward by the pressur-
before the discharge is finished, a shock may ized oil, ports C and T are opened, and the oil
occur. from the pump is drained.
Therefore, as for the clutch whose piston volume
is large, a bypass drain valve is installed and the
bypass drain valve discharges the oil without
sending the oil to ECMV to reduce the discharge
time.
* The bypass drain valve is installed in the reverse
clutch circuit.
Operation 10-50
When the solenoid valve is de-energized (in nor-
mal condition) 10-50
q As spool (2) in solenoid valve (1) is pushed right-
ward by return spring (3), chamber A and port T
are open and there is no oil pressure in chamber * This valve works for a certain period of time im-
A. mediately after the clutch is changed from the
Therefore, spool (4) in the bypass fill valve is engaged condition to the disengaged condition.
pushed rightward by return spring (5), and ports Thus, this valve does not work in normal cases
C and T are closed. (a certain period of time gone by from adjusting
clutch pressure, filling clutch, or clutch OFF).
10-50 WA1200-6
Power train
ECMV 10-51
(for transmission)
A: To clutch 1. Connector
B: Drain 2. Spring
C: From pump 3. Flow detection valve spool
P: Clutch pressure measuring port 4. Spring
5. Fill switch
6. Proportional solenoid
7. Pressure control valve spool
8. Load piston
9. Spring
WA1200-6 10-51
Power train
Outline 10-52
Outline of ECMV 10-52 ECMV and proportional solenoid 10-52
q ECMV (Electronic Control Modulation Valve) is q Single proportional solenoid is installed to each
composed of two valves: pressure control valve ECMV.
and flow detection valve. The thrust is generated as shown in the figure
q Pressure control valve based on the command current from the trans-
Valve, which converts the current which is sent mission controller
from the transmission controller and received by The thrust generated in the proportional solenoid
the proportional solenoid it into an oil pressure. is applied to the pressure control valve spool to
q Flow detection valve generates oil pressure as shown in the figure.
This valve is activated by a trigger from the pres- Thus, the thrust changes by controlling the
sure control valve and has the following func- command current to activate the pressure
tions: control valve and control the oil flow and oil pres-
1) Closes the valve as soon as oil fills in the sure.
clutch and outputs the signal (fill signal) to the
controller to inform the end of filling.
2) When the clutch is applied oil pressure,
outputs the signal (fill signal) to the controller
to inform whether oil pressure is present.
A Range: before gear shift (draining)
B Range: filling start (triggering)
C Range: filling end
D Range: adjusting pressure
E Point: filling
ECMV and fill switch 10-52

q Single fill switch is installed to each ECMV.
When the clutch finishes filling, the fill switch is
turned ON by the flow detection valve. The oil
pressure starts build-up based on this signal.
10-52 WA1200-6
Power train
Operation 10-53
Operation of ECMV 10-53 1. Before gear shift (draining) (range A in the
q ECMV is controlled by the command current diagram)
sent to proportional solenoid from the transmis- When the current does not flow in proportional
sion controller and the fill switch output signal. solenoid (6), the repulsive force of spring (9) for
The following figure below shows the relations the pressure control valve thrusts back propor-
among the command current to proportional tional solenoid (6) through pressure control
solenoid, the clutch input pressure, and the fill valve spool (7), so pressure control valve spool
switch output signal. (7) drains the oil in clutch port C through drain
port E.
A Range: before gear shift (draining) At this time, as the oil pressure does not act on
B Range: filling start (triggering) flow detection valve spool (3), flow detection
C Range: filling end valve spool (3) is put away from fill switch (5) by
D Range: adjusting pressure the repulsive force of fill switch spring (4) and
E Point: filling stands still in the position where it balances with
return spring (2) of the flow detection valve.
WA1200-6 10-53
Power train
2. When the filling starts (trigger command is input 3. When the filling ends (set the pressure control
into the pressure control valve) (range B in the valve to initial pressure) (range C in the diagram)
diagram) 1) After a certain period of time, the flow rate of
When the trigger current is applied (maximum oil for filling the clutch is dropped down by
current is applied) to proportional solenoid (6) reducing the current value of proportional
while no oil exists in the clutch, proportional sole- solenoid (6) to an initial pressure level,
noid (6) moves to the stroke end to move pres- moving pressure control valve spool (7) right-
sure control valve spool (7) leftward. This opens ward, and throttling the path between pump
pump port A and pressure control valve port B port A and pressure control valve port B. This
open and starts to fill the clutch with oil through enabled to prevent the occurrence of peak
orifice a of flow detection valve spool (3). pressure in clutch port C when the filling ends
and change the gear shift smoothly.
10-54 WA1200-6
Power train
2) When the clutch is filled with oil, the oil flow 4. Adjusting pressure (range D in the diagram)
stops from output port B of the pressure When the current flows in proportional solenoid
control valve to clutch port C. As the right and (6), the solenoid generates force in proportion to
left reception areas of flow detection valve the current. The pressure is adjusted by this
spool (3) are different from each other and thrust of solenoid, the thrust from the oil pressure
the left reception area is larger than the right of clutch port C applied to load piston (8), and the
one, when the oil pressures of both sides are repulsive force of pressure control valve spring
equal to each other, flow detection valve (9).
spool (3) moves rightward with the oil pres- Flow detection valve spool (3) is pressed right-
sure. At this time, flow detection valve spool ward by the difference between the oil pressures
(3) compresses fill switch spring (4) based on applied on both sides to continue to output the fill
the area difference between right and left signal to the controller.
sides and tension of return spring (2) of flow
detection valve, and moves rightward to
come into contact with fill switch (5) and
informs to the controller that the clutch
finished the filling. At this time, the current at
initial pressure level flows to proportional
solenoid (6) and the oil pressure of pressure
control valve spool (7) is set to an initial pres-
sure.
WA1200-6 10-55
Power train
Transmission lubricating oil relief valve
Transmission lubricating oil relief valve 10-56
A: To transmission lubrication circuit

B: From torque converter oil cooler
P: Lubricating oil pressure measuring port
T: Drain
1. Spool
2. Valve body
Function 10-56
q The translation lubricating oil relief valve is in-
stalled on the transmission valve and prevents
unusual pressure of transmission lubricant oil.
Set pressure: 0.26 MPa {3.0 kg/cm2} (cracking
pressure)
10-56 WA1200-6
Power train
Transfer
Transfer 10-57
1. Transmission output shaft

2. Transfer input gear (number of teeth: 38)
3. Transfer idler gear (number of teeth: 57)
4. Transfer output gear (number of teeth: 40)
5. Output shaft
6. Front coupling
7. Strainer
8. Rear coupling
9. Parking brake
Outline 10-57
q The transfer is installed on the output side of the
transmission and is fixed to the transmission
case with bolts
WA1200-6 10-57
Power train
Transfer
Operation 10-58
q The power from transmission output shaft (1) is

transmitted as follows:
Transmission output shaft (1) (from lower left)

O O
Transfer input gear (2) Output shaft (5) o
O O O
Transfer idler gear (3) Center drive shaft
O O O
Transfer output gear (4) Front drive shaft Rear drive shaft
O O O
(to upper right) Front axle Rear axle
10-58 WA1200-6
Power train
Torque converter oil cooler
Torque converter oil cooler 10-59
1. Torque converter oil cooler Outline 10-59

q The torque converter oil cooler is installed on the
A. Oil inlet port bottom of the engine oil pan. The oil output from
(from torque converter regulator valve) the torque converter is at a high temperature due
B. Oil outlet port (to transmission lubrication) to the power train energy. This torque converter
C. Water inlet port (from water pump) oil enters through oil cooler port A into the oil
D. Water outlet port (to engine block) cooler and is cooled by the engine coolant.
Then, the oil lubricates the transmission from oil
outlet port B and returns to the transfer case.
WA1200-6 10-59
Power train
Center support
Center support 10-60
1. Front coupling Function 10-60

2. Case q The center support is installed on the front frame
3. Grease nipple between center and front drive shafts
4. Rear coupling q In the case of the articulate frame, this part al-
ways repeats bend, and the drive shaft is subject
to the high stress. Therefore, the center support
is employed so that the power is transmitted
smoothly and the durability of the drive shaft is
enhanced.
10-60 WA1200-6
Power train
Axle
Axle 10-61
Front axle 10-61
1. Front axle
2. Differential
3. Front brake
4. Final drive
5. Drain plug
WA1200-6 10-61
Power train
Axle
Front differential 10-62
1. Differential housing
2. Bevel gear (number of teeth: 39)
3. Differential side gear (number of teeth: 28)
4. Differential pinion gear (number of teeth: 22)
5. Shaft
6. Bevel pinion (number of teeth: 10)
7. Coupling
10-62 WA1200-6
Power train
Axle
Rear axle 10-63
1. Rear axle
2. Differential
3. Rear brake
4. Final drive
5. Drain plug
WA1200-6 10-63
Power train
Axle
Rear differential 10-64
1. Bevel pinion (number of teeth: 10)

2. Bevel gear (number of teeth: 39)
3. Shaft
4. Differential pinion gear (number of teeth: 22)
5. Differential side gear (number of teeth: 28)
6. Differential housing
7. Coupling
10-64 WA1200-6
Power train
Axle
Outline 10-65 At straight-travel 10-65

q The power from the engine is transmitted q When traveling straight, the speeds of right and
through the damper, upper drive shaft, modula- left wheels are the same, so pinion gear (4) in
tion clutch, torque converter, transmission, and differential Ass'y does not rotate, but the power
drive shaft to the front and rear axles. of carrier (6) is evenly transmitted through pinion
q In the axle, the power is transmitted from pinion gear (4) and side gear (3) to right and left axle
gear (1) to bevel gear (5), then the transmission shafts (2).
of the power changes 90 degrees in direction,
reduces speed, and is transmitted through differ-
ential (4) to axle shaft (2).
q The power in the axle shaft is decelerated by the
planetary gear type final drive and is transmitted
to wheels.
At swing 10-65
q When turning, the speeds of right and left wheels
are different from each other, so pinion gear (4)
and side gear (3) in the differential transmits the
power of carrier (6) to the axle shaft (2) accord-
ing to the difference between right and left
speeds.
WA1200-6 10-65
Power train
Final drive
Final drive 10-6
1. Axle shaft Outline 10-6

2. Brake q In order to get large driving force, the final drive
3. Ring gear (number of teeth: 81) reduces the speed and transmits the driving
4. Ring gear (number of teeth: 76) force to the wheels by utilizing the planetary gear
5. Sun gear (number of teeth: 21) mechanism.
6. Sun gear (number of teeth: 28) q The power transmitted from the differential
7. Drain plug through axle shaft (1) to 1st sun gear (5) is trans-
8. Planetary gear (number of teeth: 23) mitted to planetary gear (9), and as the planetary
9. Planetary gear (number of teeth: 29) gear rotates in the fixed ring gear (3), the power
10. Housing is transmitted to 2nd sun gear (6). Similar to 1st
11. Wheel sun gear, decelerated rotation travels to the
12. Thrust spacer planetary gear and the power is transmitted to
13. Plate wheel (11) mounted on the carrier.
14. Shaft
10-66 WA1200-6
Steering system
Steering equipment layout drawing
Steering system 10-67

Steering equipment layout drawing 10-67
1. Steering demand valve (right)

2. Rotary valve
3. AJSS lever
4. Hydraulic tank
5. Switch pump
6. Steering pump
7. EPC valve
8. Steering demand valve (left)
9. Steering cylinder
WA1200-6 10-67
Steering system
AJSS
AJSS 10-68
* AJSS: Advanced joystick steering system
a For information on the operation, refer to the section "Work equipment, AJSS controll system"
1. Steering lock lever

2. AJSS lever knob
3. Rod
4. Rotary valve
5. Potentiometer (frame angle)
6. Front frame
7. Bracket
8. Joint
9. Lever
10-68 WA1200-6
Steering system
AJSS
WA1200-6 10-69
Steering system
Steering pump
Steering pump 10-70

Model: HPV160 + 160 + SAR(2)71 + +63
10-70 WA1200-6
Steering system
Steering pump
Outline 10-71
q The steering pump is composed of two variable
displacement swash plate type piston pumps,
PC valve, LS valve, and two gear pumps.
q For more information on HPV160 + 160 pump,
LS valve, and PC valve, refer to switch pump
section.
PAD1: Gear pump discharge port

PAF: Front pump discharge port
PAR: Rear pump discharge port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Front case drain plug
PD2R: Rear case drain plug
PENF: Front control pressure pickup port
PENR: Rear control pressure pickup port
PFC: Front pump delivery pressure pickup port
PGS1: Gear pump suction port
PLSF: Front load pressure input port
PLSFC: Front load pressure pickup port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
1. Front piston pump (HPV160)

2. Rear piston pump (HPV160)
3. LS valve
4. PC valve
5. Hydraulic control pump (SAR(2) 71)
6. PPC pilot pump (SAR(2) 63)
WA1200-6 10-71
Steering system
Switch pump
Switch pump 10-72

Model: HPV160 + 160 + SAR(3)125 + 100
10-72 WA1200-6
Steering system
Switch pump
Outline 10-73
q The switch pump is composed of two variable
displacement swash plate type piston pumps,
PC valve, LS valve, and two gear pumps.

PAF: Front pump discharge port
PAR: Rear pump discharge port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Case drain port
PD1R: Air bleeder
PD2F: Front case drain plug
PD2R: Rear case drain plug
PENF: Front control pressure pickup port
PENR: Rear control pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front load pressure input port
PLSFC: Front load pressure pickup port
PLSR: Rear load pressure input port
PLSRC: Rear load pressure pickup port
PRC: Rear pump delivery pressure pickup port
1. Front piston pump (HPV160)

2. Rear piston pump (HPV160)
3. LS valve
4. PC valve
5. Hydraulic cooling pump (SAR(3) 125)
6. Hydraulic cooling pump (SAR(3) 100)
WA1200-6 10-73
Steering system
Switch pump
Model: HPV160 + 160 pump 10-74

Outline 10-74
q The piston pump model for the steering pump
and switch pump is HPV160 + 160, and the
same pump is used.
10-74 WA1200-6
Steering system
Switch pump
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston
WA1200-6 10-75
Steering system
Switch pump
Function 10-76
q The engine rotation torque transmitted to the
pump shaft is converted into the hydraulic pres-
sure and the pressurized oil corresponding to
the load is discharged.
q It is possible to change the delivery amount by
changing the swash plate angle.
Structure 10-76
q Cylinder block (7) is secured on splined area
(14) of shaft (1).
q Shaft (1) is supported by each bearing (15) at the
front and rear.
q The tip of piston (6) is shaped as a concave
sphere and is crimped on shoe (5).
q Piston (6) and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while slid-
ing in a circular pattern.
q Rocker cam (4) conducts high pressure oil to cyl-
inder surface (B) contacted with cradle (2), which
is secured to the case, and forms a static pres-
sure bearing when it slides.
q Piston (6) performs the reciprocation axially in-
side each cylinder chamber of cylinder block (7).
q Cylinder block (7) seals the pressurized oil to
valve plate (8) and performs relative rotation.
q This surface is designed so that the oil pressure
balance is maintained at a suitable level.
q The oil is sucked into and discharged from each
cylinder in cylinder block (7) through valve plate
(8).
10-76 WA1200-6
Steering system
Switch pump
Operation of pump 10-7

q Cylinder block (7) rotates along with shaft (1) q When center line (X) of rocker cam (4) matches
and shoe (5) slides on plane (A). the axis of cylinder block (7) (the swash plate an-
q Rocker cam (4) moves along cylindrical surface gle is 0), the difference between volumes (E) and
(B). As a result, angle (a) between center line (X) (F) inside in cylinder block (7) is zero.
of rocker cam (4) and the axis of cylinder block q Suction and discharge of pressurized oil is not
(7) changes. performed in this stage. Namely pumping action
q Angle (a) is called the swash plate angle. is not performed. (Actually, however, a zero
swash plate angle never occurs.)
q If an angle (a) is made between center line (X) of

rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) in cylinder block (7).
q Each piston (6) sucks and discharges oil by (F) -
(E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E) during this process.
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F) during this process.
WA1200-6 10-77
Steering system
Switch pump
Control of delivery 10-78

q When swash plate angle (a) increases, the dif-
ference between volumes (E) and (F) increases,
and delivery (Q) also increases.
q Swash plate angle (a) is changed with servo pis-
ton (12).
q Servo piston (12) makes in a linear reciprocating
movement according to the signal pressures
from the PC and LS valves.
q This linear motion is transmitted by way of slider
(13) to rocker cam (4).
q Rocker cam (4) supported by cradle (2) on the
cylindrical surface rotates and slides.
q Servo piston (12) has a different pressure re-
ceiving areas on the right and left side, and the
delivery pressure (self pressure) (PP) of main
pump is always led to the pressure chamber of
small diameter piston.
q Output pressure (PEN) of LS valve is led to the
pressure chamber of the large diameter piston.
q The movement of servo piston (12) is controlled
by the relation of the pressure between small di-
ameter piston side (PP) and large diameter pis-
ton side (PEN) and by the ratio of the areas
where receiving the pressure of the small diam-
eter piston and large diameter piston.
10-78 WA1200-6
Steering system
Switch pump
1. LS valve 10-79
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: Drain port 7. Plug
8. Locknut
Function 10-79
q The LS (load sensing) valve detects the load of
the actuator and controls the discharge amount.
q This valve controls pump delivery (Q) with the
differential pressure (dPLS) [= (PP) - (PLS)]
(called the LS differential pressure) between
pump delivery pressure (PP) and control valve
outlet pressure (PLS).
q The main pump pressure (PP) and pressure
(PLS) (called an LS pressure) led from control
valve output are input to this valve.
q The figure shows the relation among main pump
pressure (PP), LS pressure (dPLS)
[=(PP–PLS)], and delivery (Q).
WA1200-6 10-79
Steering system
Switch pump
Operation 10-80
1) When control valve is in NEUTRAL position: 10-80
q The LS valve is a 3-way selector valve, and pres- q By the area difference of servo piston (12), the
sure (PLS) LS pressure from the control valve in- servo piston moves in such a direction that the
let is transmitted to spring chamber (B), and swash plate angle is minimized.
pump delivery pressure (PP) is transmitted to
port (H) of sleeve (8).
q The magnitude of the force resulting from this LS
pressure (PLS), the force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (6).
q Before the engine is started, servo piston (12) is
pushed to the left. (See the figure on the right)
q If the control lever is in the neutral position when
the engine is started, LS pressure (PLS) is set to
0 MPa {0 kg/cm2}. (It is interconnected to the
drain circuit via the control valve spool)
q Spool (6) is pushed to the right, and port (C) and
port (D) are connected.
q Pump pressure (PP) is transmitted to the larger
diameter end of the pump from the port (K).
q The same pump pressure (PP) is transmitted to
the smaller diameter end of the pump at the port
(J).
10-80 WA1200-6
Steering system
Switch pump
2) Move to increase the pump delivery: 10-81
q When the difference between pump delivery

pressure (PP) and LS pressure (PLS), namely
LS differential pressure (dPLS) decreases (for
example, the opening area of control valve in-
creases and the pump delivery pressure (PP)
decreases), the combined force of LS pressure
(PLS) and the force of spring (4) pushes spool
(6) to the left.
q When spool (6) moves, ports (D) and (E) are
connected to each other and to the PC valve.
q Since the PC valve and drain port are connect-
ed, the pressure between circuits (D) and (K) be-
comes drain pressure (PT). (PC valve operation
will be explained later.)
q The pressure on the large diameter piston side
of servo piston (12) becomes drain pressure
(PT), and pump pressure (PP) is constantly ap-
plied to port (J) on the small diameter side. Ac-
cordingly, servo piston (12) is pushed to the left
and the swash plate is moved to increase the de-
livery.
WA1200-6 10-81
Steering system
Switch pump
3) Move to decrease the pump delivery: 10-82
q When servo piston (12) moves to the right (the

direction in which pump delivery reduces) and
the LS differential pressure (dPLS) increases
(for example, the opening area of control valve
decreases and the pump delivery pressure (PP)
increases), the force of pump delivery pressure
(PP) pushes spool (6) to the right.
q The movement of spool (6) transmits pump de-
livery pressure (PP) to the large diameter end of
the piston through port (C), port (D) and port (K).
q Though pump delivery pressure (PP) enters the
small diameter piston port (J), because of the
area difference between the large diameter pis-
ton and the small diameter piston in servo piston
(12), servo piston (12) is pushed to the right.
Thus it moves to the direction in which the swash
plate angle decreases.
10-82 WA1200-6
Steering system
Switch pump
4) When servo piston is balanced: 10-83
q The symbols (A1), (A0) and (PEN) represent the q The force of spring (4) is adjusted so that spool
area receiving the pressure at the large diameter (6) is balanced at this position when (PP - PLS)
end of the piston, the area receiving the pressure =1.37 MPa {14 kg/cm2} at the center based on
at the small diameter end and the pressure con- the standard.
ducted to the large diameter end of the piston,
respectively.
q When the force exerted by main pump pressure
(PP) of the LS valve is balanced with the com-
bined force of LS pressure (PLS) and spring (4),
and the relation becomes (A0) x (PP) = (A1) x
(PEN), servo piston (12) stops in that position.
q The swash plate of the pump is held in interme-
diate position. [Stops at the position where the
opening area of port (D) to port (E) in spool (6) is
almost equal to that of port (C) to port (D)]
q The relation of pressure receiving areas at both
ends of servo piston (12) is (A0):(A1) = 3:5 and
the pressures applied to both ends of piston
when the piston is balanced is (PP):(PEN)C =
5:3.
WA1200-6 10-83
Steering system
Switch pump
2. PC valve 10-84
PA: Pump port 1. Plug

PA2: Pump pressure pilot port 2. Servo piston assembly
PDP: Drain port 3. Pin
PPL: Control pressure output port (to LS valve) 4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function 10-84
q When the pump delivery pressures (PP1) (self
pressure) and (PP2) (other pump pressure) are
high, PC valve controls the flow rate to a certain
amount corresponding to the delivery pressure
even if how much the travel of the control valve
increases.
q If the pump delivery pressure increases due to
the increased load during work, this valve de-
creases the pump delivery.
q And if the pump delivery pressure goes low, it in-
creases the pump delivery.
q In this case, the figure on the right shows the re-
lation between average delivery pressure (PP1 +
PP2)/2 of the front and rear pumps, and pump
delivery (Q).
10-84 WA1200-6
Steering system
Switch pump
Operation 10-85
(1) When load to actuator is small and pump pressures (PP1), (PP2) are low 10-85
q Spool (2) stops at the position where the com-

bined force of the spring set force of spring (3),
pump pressures (PP1) (self pressure) and (PP2)
(other pump pressure) are balanced.
q Pressure output from PC valve
[pressure at port (C)] changes according to the
position.
a The pressure of other pump denotes the pres-
sure of the pump situated on the opposite side.
For the front pump pressure, the pressure of
other pump is that of the rear pump.
And for the rear pump pressure, the pressure of
other pump is that of the front pump.
WA1200-6 10-85
Steering system
Switch pump
Action of spring
q The spring load of spring (3) is determined for q Spring (3) extends according to the movement of
PC valve according to the position of the swash servo piston (4) to reduce the spring force.
plate. q When the spring force is reduced, spool (2)
q As servo piston (4) moves to the right spring (3) moves to the right, ports (C) and (D) are shut off,
is compressed. and port (B) with pump delivery pressure is con-
q Servo piston (4) changes the spring load by ex- nected to port (C).
tending or compressing spring (3). q As the pressure of port (C) increases and the
q Port (C) of the PC valve is connected to port (E) pressure of larger piston side increases, the
of the LS valve. movement to the left of servo piston (4) stops.
q Self pressure (PP1) enters into the small diame- q The stop position (= pump delivery) of servo pis-
ter piston side of servo piston (4) and port (B), ton (4) is determined when the force caused by
and other pump pressure (PP2) enters into port pressures (PP1)and (PP2) applied to spool (2)
(A). and the force of spring (3) are balanced.
q When the pump pressures (PP1)and (PP2) are
small, spool (2) is in the left position.
q When ports (C) and (D) are connected to each
other, the pressure entering into LS valve be-
comes drain pressure (PT).
q When ports (E) and (G) are connected to each
other in the LS valve, the pressure entering from
port (J) into large diameter piston side and servo
piston (4) moves to the left.
q The pump delivery increases.
10-86 WA1200-6
Steering system
Switch pump
(2) When load on actuator is large and pump delivery pressure (PP) is high 10-87
Outline 10-87
q When a load is large and pump delivery pres- q When spool (2) moves to the left, the opening of
sures (PP1)and (PP2) are high, the force to push ports (C) and (D) increases further.
spool (2) to the right increases, and spool (2) is q The pressure (= J) of port (C) decreases, and the
in the position shown in the figure above. movement to the right of servo piston (4) stops.
q As a part of pressure from port (B) flows through q At this time, servo piston (4) stops at the further
LS valve and port (C) into port (D), as shown in right position than that when pump pressures
the figure above, the pressure flowing from port (PP1) and (PP2) are low.
(C) into LS valve becomes about a half of pump q The bent line graph shows the positional rela-
pressure (PP2). tions between average pump pressure (PP1 +
Operation 10-87 PP2)/2 and servo piston (4).
q When ports (E) and (G) of LS valve are connect- q The relation between the average pump pres-
ed to each other, this pressure from port (J) ensure (PP1+PP2)/2 and average pump delivery
ters into large diameter piston side in servo (Q) is shown below.
piston (4) to stop servo piston (4).
q When pump pressures (PP1) and (PP2) in-
crease further, and spool (2) moves rightward,
pump pressure (PP1) is transmitted to port (C),
and this moves piston (4) so that the pump deliv-
ery decreases to minimum.
q When servo piston (4) moves to the right, spring
(3) is compressed to push back spool (2).
WA1200-6 10-87
Steering system
Switch pump
10-88 WA1200-6
Steering system
Steering demand valve
Steering demand valve 10-89
WA1200-6 10-89
Steering system
1. Overload relief valve Main relief valve

2. Main relief valve
3. Steering spool
4. Flow control spool
5. Surge cut relief valve
A. To steering cylinder
B. To steering cylinder
LS. load sensing port
(to steering and switch pump PLSF, PLSR ports)
P1. From steering pump
P2. From switch pump
PB. To work equipment control valve
T. To hydraulic tank
(via hydraulic oil cooler) 1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function 10-90
q The main relief valve of the steering demand
valve exists in the valve and sets up the maxi-
mum pressure of the steering circuit while the
steering is in operation. That is, when the pres-
sure in the steering circuit becomes or exceeds
the set pressure of the valve during the valve op-
eration, the oil is relieved, and the flow control
spool of the demand valve works to drain the oil
into the steering circuit.
Overload relief valve
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
10-90 WA1200-6
Steering system
Function 10-91 q When pilot poppet (4) opens, the pressure on the
q The overload relief valve is installed in the cylin- back of poppet (1) decreases, and poppet (1)
der circuit of the steering demand valve. When moves rightward to seat on pilot poppet (4).
any impact is applied to the steering cylinder and
an unusual pressure occurs while the demand
valve is in neutral, there are the safety valve
function which prevents the damage of the cylin-
der or hydraulic piping by relieving the pressure
through this valve and the function which pre-
vents a vacuum when negative pressure occurs
in the cylinder.
Operation 10-91
1. Action of relief valve 10-91
q Port A is connected to the cylinder circuit, and
port B to the drain circuit. The oil goes through a
hole in poppet (1) and acts on the areas of diam-
eters d1 and d2 to securely seat check valve q As the inside pressure is lower compared with
poppet (3) and relief valve poppet (2). the pressure of port A, the relief valve poppet (2)
opens. The oil flows from port A into port B to
prevent unusual pressure.
q When the pressure of port A reaches the set

pressure of the relief valve, the pilot poppet (4)
opens. The oil flows around pilot poppet (4) into 2. Action of suction valve 10-91
port B. q When a negative pressure occurs in port A, be-
cause of the difference between the areas of di-
ameters d3 and d4, check valve poppet (3)
opens. The oil flows from port B into port A to
prevent a vacuum in the circuit.
WA1200-6 10-91
Steering system
Action of steering relief valve 10-92
q When the circuit pressure increases to the pres- q The movement of the flow control spool (4) pre-
sure set by adjust screw (1) and spring (2), pilot vents the pressure in the steering circuit from ex-
poppet (3) opens to drain the oil. ceeding the specified value by draining the oil of
q Here, the pressures of chamber receiving pres- steering pump and flowing the oil of the switch
sure (I) and chamber receiving pressure (II) are pump into the main control valve.
not balanced, and the flow control spool (4)
moves leftward. LS load sensing port
q The LS load sensing port is connected to PLSF
and PLSR ports of the steering port and switch
pump. THe oil pressure is generated in PLSF
and PLSR ports, and moves the swash plate of
the pump to the side on which the oil flows.
10-92 WA1200-6
Steering system
Action of demand valve 10-93

When the steering spool is in neutral 10-93
q The oil from the steering pump enters into port A.

The oil from the switch pump enters into port B.
q When steering spool (2) is in neutral, pressure
receiving chamber (II) connects through orifice b
to the drain circuit, and notch c is closed.
q As notch c is closed, the oil in ports A and B in-
creases in pressure and goes through orifice a
into pressure receiving chamber (I) to move flow
control spool (1) leftward.
q When the pressure of pressure receiving cham-
ber (I) becomes a certain value (set by spring
(3)), notch f opens and the oil from the steering
pump flows into the drain circuit. Also, notch g
closes and the oil from the switch pump flows
into the main control valve.
WA1200-6 10-93
Steering system
When operating steering control valve 10-94

q Engine running at low speed
q When the steering is operated, the oil flows from q Here, the pressure before passing through notch
the rotary valve to steering spool (2) to push c is led into pressure receiving chamber I and
steering spool (2) rightward, shut off pressure re- the pressure after passing through notch c is led
ceiving chamber II and drain circuit, and open into pressure receiving chamber II. And flow
notch c. control valve spool (1) works so that the differ-
q Thus, the pressure in pressure receiving cham- ence between the pressures before and after
ber II increases, flow control spool (1) moves notch c is always maintained constant. There-
rightward until notch h closes. fore, the flow rate of oil is supplied to the cylinder
q The path from port B to the main control valve is port according to the opening of notch c. These
shut off, the oil in the switch pump opens pressure differences (control pressures) are set
merge-divider check valve (4) to merge with the up by spring (3).
oil from steering pump in port A.
q The oil merged goes through notches c and d,
pushes load check valve (5), and enters into the
cylinder. The oil returning from the cylinder flows
through notch e into the drain circuit.
10-94 WA1200-6
Steering system
q When engine is running at high speed
q As the backup oil from the switch pump is not re-

quired, the steering pump pressure rises until
notch g closes and the merge path of port B is
shut off.
q The difference between pressures before and
after notch c is controlled only by notch f, and the
surplus oil in the steering pump is drained
through notch f into the drain circuit. (Here, notch
g is completely closed.)
q The oil from the steering pump goes through
notches c and d, pushes load check valve (5),
and enters into the cylinder. The oil returning
from the cylinder flows through notch e into the
drain circuit.
q As notch g is closed, all the oil from the switch
pump flows through port B and enters into the
main control valve.
WA1200-6 10-95
Steering system
Action of steering valve 10-96

NEUTRAL 10-96
q Because the steering wheel is not activated,

steering spool (2) does not move.
q The oil from the steering pump enters into port A.
The oil from the switch pump enters into port B.
q When the pressures of ports A and B increase,
flow control spool (1) moves leftward, and the oil
from the steering pump is drained through spool
port C.
All the oil from the switch pump flows through
port D into the main control valve.
10-96 WA1200-6
Steering system
Right turn 10-97
q As the steering lever is operated to the right the

rotary valve is activated and steering spool (2)
moves leftward.
The oil from the steering pump enters into port A
and flows through flow control spool (1) into
steering spool (2) to push load check valve (6) of
the spool and the oil flows into the left cylinder
bottom and right cylinder rod side to turn the
machine to the right. The oil from the right and
left cylinders is drained through load check valve
(5) in the steering spool. The oil from the switch
pump enters into port B, pushes open check
valve (4) through flow control spool (1), and
merges with the oil from the steering pump.
WA1200-6 10-97
Steering system
Left turn 10-98
q As the steering control lever is operated to the

left, the rotary valve is activated and steering
spool (2) moves rightward.The oil from the steer-
ing pump enters port A and flows through flow
control spool (1) into steering spool (2) to push
open load check valve (5) of the spool and the oil
flows into the left cylinder rod side and right ma-
chine bottom to turn the machine to the left.
The oil from the right and left cylinders is drained
through load check valve (6) in the steering
spool. The oil from the switch pump enters into
port B, pushes open check valve (4) through flow
control spool (1), and merges with the oil from
the steering pump.
10-98 WA1200-6
Steering system
Rotary valve
Rotary valve 10-9
1. Neutral position spring a. To hydraulic tank

2. Valve body b. To steering demand valve Pb port
3. Check valve c. To steering demand valve Pa port
4. Spool d. From PPC pump
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
10. Center pin
11. Body
WA1200-6 10-99
Steering system
Rotary valve
Outline 10-10
q A steering control lever is coupled with the top of
the rotary valve. The rotary valve activates the
steering valve to select the steering direction of
the machine by changing the oil flow supplied
through EPC valve from the PCC pump and by
moving the spool of the steering demand valve.
q On the other hand, a link installed to the front
frame is coupled with the bottom of the rotary
valve to feed back the steering angle of the ma-
chine.
This always matches the position of the steering
control lever with the position of machine
steering.
Structure 10-10
q Spool (4) connects to sleeve (5) by using pin (10)
and neutral position spring (1) (When the steer-
ing lever is in neutral, the pin does not keep in
touch with the spool).
q Drive shaft (9) engages with pin (10) at its top
and bottom part and thus drive shaft (9) is cou-
pled with sleeve (5) and feedback sleeve (7).
q Feedback spool (6) connects to feedback sleeve
(7) by using pin (10) and loose spring (8) (When
the steering lever is in neutral, the pin does not
keep in touch with the spool).
q Valve body (2) has four ports and each port is
connected to the pump circuit, tank circuit, and
pilot circuits of the steering demand valve re-
spectively.
10-100 WA1200-6
Steering system
Rotary valve
Operation 10-101
q As the steering control lever is operated, rotate
spool (4) rotates against sleeve (5) by overcom-
ing neutral position spring (1).
This rotation puts the ports of spool (4) and
sleeve (5) aligns with each other to open an oil
path and the oil flows into the steering demand
valve.
If the steering control lever is operated beyond
the possible displacement of neutral position
spring (1), loose spring (8) absorbs the displace-
ment via drive shaft (9).
q When the oil flows into the steering cylinder and
the steering of the machine starts, the link in-
stalled on the front frame makes sleeve (5) ro-
tate through feedback spool (6) and drive shaft
(9) in such a direction that sleeve (5) decreases
the displacement with spool (4).
Moreover, when the steering of the machine
progresses to the position where the movement
accords with the operation amount of the
steering control lever, the displacement between
spool (4) and sleeve (5) disappears and the oil
path is shut off.
WA1200-6 10-101
Steering system
EPC valve (for steering)
EPC valve (for steering) 10-102
1. Minimum pressure assurance pressure reducing valve

2. Proportional solenoid valve
P1. From PPC pump

P2. From diverter valve
C. To rotary valve
D. To hydraulic tank
Function 10-102
q EPC valve controls the oil supply to the rotary
valve by using the proportional solenoid valve
controlled by the command current from the
work equipment and joystick controller.
q Also, the minimum pressure assurance pressure
reducing valve can work to give the minimum
pressure of oil to the rotary valve even if the pro-
portional solenoid valve fails because of a failure
in the controller system.
10-102 WA1200-6
Steering system
Diverter valve
Diverter valve 10-103
1. Check valve A. To emergency pump Function 10-103

q When the steering is inoperable due to the en-
2. Check valve B. Sensor mounting port gine stop, pump seizure, etc. while the machine
3. Check valve C. To hydraulic tank is traveling, the valve enables the steering oper-
ation by driving the emergency pump by using
4. Check valve D. To steering valve
the rotating movement in the transmission.
5. Spool E. From hydraulic tank
6. Valve body F. From steering circuit
WA1200-6 10-103
Steering system
Diverter valve
Operation 10-104
q When pump and engine are normal
When the steering pump and engine are normal, the

work equipment pump, steering pump, and switch
pump are driven by the engine, so the steering is op-
erable by sending the oil to the steering valve.
Also, the emergency pump is driven by the trans-
mission, the oil pushes and opens check valve (2)
through port A in the diverter valve and flows into
port B.
The pressurized oil from the steering pump flows
into port D to push spool (3) leftward.
So, the oil from port B flows into port C and flows
into the hydraulic tank.
10-104 WA1200-6
Steering system
Diverter valve
q When pump and engine fail while the machine is traveling
When the pump and engine fail while the machine is

traveling, the emergency pump is driven by the rota-
tion of the wheels through the transmission.
As the steering pump does not rotate, the oil is not
pressurized in port D. Therefore, spool (3) is pushed
rightward by spring (4).
The oil from the emergency pump flows through
ports A and B into the rotary valve, and the steering
is operable.
Note: The emergency pump can rotate either direc-

tion, forward or reverse.
WA1200-6 10-105
Steering system
Emergency steering relief valve
Emergency steering relief valve 10-106
q When the pressures in ports A and B reach to

the set force (set pressure) of poppet spring, pi-
lot poppet (3) opens, and the oil pressure of port
B is released through port D to port C to reduce
the pressure in port B.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Set pressure: 20.6 MPa {210 kg/cm2}
q When the pressure in port B decreases, the ori-
Function 10-106 fice in main valve (1) causes differential pressure
q As the rated pressure of both emergency steer- between ports A and B, the pressure in port A
ing pump and diverter valve is 20.6 MPa opens main valve (1) to release the oil in port A.
{320 kg/cm2} while the relief pressure of steering
valve is 31.4 MPa {210 kg/cm2}, the relief valve
is installed on the piping between the diverter
valve and the steering lock valve for protecting
the emergency steering pump and diverter
valve. When the steering oil pressure exceeds
20.6 MPa {210 kg/cm2} while the emergency
steering is working, the relief valve starts to op-
erate.
Operation 10-106
q Port A is connected to the pump circuit and port
C is connected to the drain circuit. The oil is filled
in port B through orifice in main valve (1). And,
pilot poppet (3) seats on valve seat (2).
10-106 WA1200-6
Steering system
Steering lock valve
Steering lock valve 10-107
1. Steering lock lever

2. Steering lock valve Ass’y
3. Lever
4. End cap
5. Ball
6. Seat
7. Body
Outline 10-107
q The steering lock valve is installed between EPC
valve and rotary valve. When steering lock lever
(1) is moved in "lock" position steering lock valve
Ass'y (2) works, in conjunction with steering lock
lever (1) and the oil in EPC circuit is shut off and
the steering operation is disabled.
WA1200-6 10-107
Brake system
Brake equipment layout drawing
Brake system 10-108

Brake equipment layout drawing 10-108
1. Front brake (right) 11. Brake valve (left)

2. Brake valve (right) 12. Front brake (left)
3. Parking brake switch 13. Slack adjuster (front)
4. Rear brake (right) 14. Charge valve
5. Slack adjuster (rear) 15. Strainer
6. Torque converter, transmission, brake cooling, 16. Parking brake solenoid valve
brake pump 17. Check-valve Ass'y of parking brake circuit
7. Rear brake (left)
8. Brake tank
9. Parking brake (with built-in transmission)
10. Accumulator
10-108 WA1200-6
Brake system
Brake valve
Brake valve 10-109

Brake valve (right)
1. Brake pedal (right and left brakes) 9. Spool (left brake)

2. Rod (right brake) 10. Cylinder (left brake)
3. Pilot piston (right brake)
4. Spool (right brake) A. Pilot port (right brake)
5. Upper cylinder (right brake) B. To rear brake (right brake)
6. Spool (right brake) C. To front brake (right brake)
7. Lower cylinder (right brake) D. Drain (right and left brakes)
8. Rod (left brake) E. To pilot port (left brake)
WA1200-6 10-109
Brake system
Brake valve
Brake valve (left)
Outline 10-1 0
q Two brake valves are mounted on the lower front
of the operator's seat in parallel with each other
and are activated by depressing the pedal.
q As the right pedal is depressed the oil is sent to
the brake cylinder to activate the brake.
q As the left pedal is depressed the oil is sent to
the right pedal to activate the brake, such as
when the right pedal is treaded. Also, the left
brake pedal activates the transmission solenoid
valve electrically by using the transmission
cut-off switch to put the transmission in neutral.
10-110 WA1200-6
Brake system
Brake valve
Operation 10-1 1
When brake is activated (right brake valve) 10-1 1
Upper part 10-1 1
q When pedal (1) is depressed the depressing ef-
fort is transferred through rod (2) and spring (4)
to spool (3). When spool (3) goes down, the
drain port a closes, and the oil from the pump
and accumulator flows through port A into port C
to activate rear brake cylinder.
Lower part 10-1 1

q When pedal (1) is depressed the depressing ef-
fort is transferred through rod (2) and spring (4)
to spool (3). When spool (3) goes down, spool
(5) goes down through plunger (6). Thus, the
drain port b closes, and the oil from the pump
and accumulator flows through port B into port D
to activate front brake cylinder.
1
2
3
Dr a i n
4
a C
A c c u mu l a t o r
A
F r o mp u mp Tor ear br ak e
A c c u mu l a t o r c y l i nder
b 6
5
F r o mp u mp Tof r ont br ak e
c y l i nder
B D
A 4 W1 1 4 5 1
WA1200-6 10-111
Brake system
Brake valve
When the brake is activated (left brake valve) 10-1 2

q When pedal (7) is depressed spool (10) is
pushed down through rod (8) and spring (9) to
close drain port c. The oil from the pump and ac-
cumulator flows through port E into port F.
q As port F in the left brake valve is connected to
port PP in the right brake valve with a hose, the
oil flown into port F flows into pilot port PP in the
right brake valve.
q The oil flown into pilot port PP flows through ori-
fice d into port G to push pilot piston (11) and
push down spool (3) through a spring, similarly
when right brake valve is treadled.
10-112 WA1200-6
Brake system
Brake valve
Brake operation when upper valve fails (right Lower part 10-1 3
brake valve) 10-1 3 q Spool (3) moves upward in the upper part and
q Even if the oil leaks in the upper piping, moved the path between ports A and C is shut off, and
down by depressing pedal (1) spool (5) is me- at the same time, the oil is filled in the front brake
chanically. The lower valve works properly. cylinder, the oil pressure increases between
The upper brake does not work. ports B and D, and the oil entered through orifice
f in spool (5) into port J pushes up spool (5) by
Brake operation when lower valve fails (right the same amount as the moving amount of the
brake valve) 10-1 3 spool (3) to shut off ports B and D. Also, as the
q Even if the oil leaks in the lower piping, the upper drain port b is closed, the oil entered into the
part works properly. brake cylinder is kept, and the brake is kept
working.
q The pressure in the upper space is balanced
with the depressing force of pedal, and the pres-
sure in the lower space is balanced with that in
the upper space. When spools (3) and (5) travel
in the full stroke, the paths open completely be-
tween ports A and C and between ports B and
D. The oil pressures in the spaces in upper and
lower parts and the oil pressures in the right and
left brake cylinders become equal to the oil pres-
sure from the pump.
Therefore, until the piston travels in the full
stroke, the effect of the brakes can be adjusted
by depressing the pedal.
When brake works with balance 10-1 3

Upper part 10-1 3
q When the oil is filled in the rear brake cylinder
and the oil pressure increases between ports A
and C, the oil entered through orifice e in spool
(3) into port H pushes up spool (3) against spring
(4) to shut off ports A and C. Here, drain port a is
still closed, the oil entered into the brake cylinder
is kept, and the brake is kept working.
WA1200-6 10-113
Brake system
Brake valve
When brake is released (right brake valve) 10-1 4

Upper part 10-1 4
q When pedal (1) is released and the depressing
effort is eliminated from the top of the spool, the
back-pressure from the brake cylinder and the
spool return spring move spool (3) upward to re-
lease drain port a, and the oil from the brake cyl-
inder flows into the return circuit to the hydraulic
tank and the rear brake is released.
Lower part 10-1 4

q As soon as the pedal is released and spool (3) in
the upper part moves upward, the back-pressure
from the brake cylinder and the spool return
spring move spool (5) to release drain port b,
and the oil from the brake cylinder flows into the
return circuit to the tank and the front brake is re-
leased.
10-114 WA1200-6
Brake system
Charge valve
Charge valve 10-1 5
ACC: Plug Function 10-1 5

PP: To brake valve q The charge valve works so that the oil pressure
P: From pump from the pump can be maintained in the speci-
T: To brake oil tank fied pressure and charges the accumulators.
q When the oil pressure becomes the specified
pressure, the oil pressure from the pump flows to
the drain circuit to relieve the pump load.
WA1200-6 10-115
Brake system
Charge valve
1. Main relief valve (R3)

2. Valve body
3. Relief valve (R1)
4. Relief valve (H1)
5. Filter
6. Filter
10-116 WA1200-6
Brake system
Charge valve
Operation 10-1 7
1. When the oil is not supplied to the accumu- 2. When oil is supplied to the accumulator
lator 1) cutin condition
(cutout condition) q When the pressure in port B is less than
q As the pressure of port B is higher than the or equal to the set pressure of relief valve
set pressure of relief valve R1, the oil pres- R1, piston (8) is pushed back downward
sure of port B pushes piston (8) upward forc- by spring (5). As a result, valve seat (7)
ibly to open poppet (6) and make a short out comes into tight contact with poppet (6)
between ports C and T. and port C is shut off from port T.
q As the rightmost spring chamber in spool (15) q The right spring chamber in spool (15) is
leads to port C in relief valve R1, the pressure shut off from port T, so its pressure in-
is the same as the one in the tank. creases, and similarly, the pressure of
The oil from the pump enters into port P to port P increases.
push spool (15) rightward with low pressure q When the pressure of port P reaches the
corresponding to the load of spring (14) and pressure of port B (accumulator pres-
flows in the tank through orifices (17), (18), sure) or higher, the oil supply starts to the
(16). accumulators. In this case, the supply
amount is determined by the size (area)
of orifice (17) and the pressure difference
occurred (equivalent to the load of spring
(14)). A fixed amount is supplied regard-
less of the engine speed.
WA1200-6 10-117
Brake system
Charge valve
2) When the pressure reaches to cutout pres- 3. Main relief valve (R3)
sure q When port P (pump pressure) reaches the set
q When the pressure of port B (accumulator pressure of relief valve R3 or higher, the oil from
pressure) reaches to the set pressure of re- the pump pushes up pole (11) against spring (3)
lief valve R1, poppet (6) gets away from valve to lead the oil into the tank circuit so that the
seat (7), the oil flows to start a relief opera- maximum pressure in the brake circuit is regu-
tion. late and the circuit is protected.
q As the relief operation is started, a pressure
difference occurs between the upper and
lower sides of piston (8), thus piston (8)
moves upward to open poppet (6) forcibly
and makes a short out between ports C and
T.
q As the rightmost spring chamber in spool (15)
is connected to port C in relief valve R1, the
pressure is the same as the one in the tank.
q Similarly, the pressure in port P decreases to
the pressure equivalent to the load of spring
(14) and the oil to port B supply stops.
10-118 WA1200-6
Brake system
Accumulator (for brake)
Accumulator (for brake) 10-1 9
1. Accumulator (2 pcs)
2. Accumulator (1 pc)
3. Plug
4. Gas valve
5. Top cover
6. Cylinder
7. Free piston
Function 10-1 9 Specifications 10-1 9

q There are two types of accumulators, (1) and (2). Gas used: nitrogen gas
The accumulators are installed between each Gas capacity: Accumulator (1): 20 l
charge valve and brake valve, and absorb the Accumulator (2): 3.5 l
pulsation of hydraulic pump and secure the brak- Charge pressure: Accumulator (1)
ing force and operability while the engine stops : 11.8 ± 0.49 MPa {120 ± 5 kg/cm2}
by filling the nitrogen gas between cylinder (6) Accumulator (2)
and free piston (7) and using the compressibility
: 10.7 ± 0.34 MPa {109 ± 3.5 kg/cm2}
of it.
WA1200-6 10-119
Brake system
Slack adjuster
Slack adjuster 10-120
1. Bleeder Specifications 10-120

2. Cylinder q Piston operation oil pressure:
3. Check valve 0.01(+0.001/0) MPa {0.1 (+0.01/0) kg/cm2}
4. Piston q Check valve cracking pressure:
5. Spring
1.74±0.05MPa {17.8 ± 0.5 kg/cm2}
q Check valve closing pressure:
A: Inlet port
B: Outlet port 1.09±0.05MPa {11.1 ± 0.5 kg/cm2}
Function 10-120
q The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston and
keeps a constant time lag by maintaining con-
stant clearance between the brake piston and
disc even if the brake disc wears out when the
brake works.
10-120 WA1200-6
Brake system
Slack adjuster
Operation 10-121
1. When the brake pedal is depressed 10-121
q Piston (4) before depressing the brake is moved
back by stroke S (full stroke). When the brake
pedal is depressed, the oil discharged from the
brake valve flows through port P in the slack ad-
juster into right and left cylinders (2) to move pis-
ton (4) rightward and leftward by stroke S.
2. When brake pedal is released 10-121

q When the brake is released, piston (4) is moved
back for the oil amount of stroke S caused by
brake return spring (8) and the brake is returned
to the released condition.
That is, return travel T of brake piston (7) is
determined by the oil amount of stroke S in the
slack adjuster, and the braked time lag is always
q Whereby, brake piston (7) moves by stroke S. At constant regardless of the wear amount.
this time, the relation between the brake piston
and disc is that the clearance becomes zero, but
the brake force does not occur.
q When the brake pedal is kept depressed further,

the pressure of oil discharged from the brake
valve exceeds the specified value, and check
valve (3) opens and the pressure acts on port C
as a brake force.
Thus, the time lag when the brake is applied is
maintained constant.
WA1200-6 10-121
Brake system
Brake
Brake 10-12
1. Guide pin Operation 10-12

2. Brake piston q When the brake pedal is depressed brake piston
3. Return spring (2) moves to the right to contact and lock disc (5)
4. Floating seal and plate (4) closely. As disc (5) is rotating along
5. Disc with the wheel, the rotation stops by the lock, the
6. Plate brake is applied, and the machine stops. When
the brake pedal is released the back pressure of
Function 10-12 piston (2) is released. The piston moves to the
q The service brake is installed in four wheels and left with the force of return spring (3) to release
has wet multiple disc structure. the brake.
10-122 WA1200-6
Brake system
Parking brake
Parking brake 10-123
A. Piston room Outline 10-123

q The parking brake is a wet multiple disc brake
1. Rear coupling which is activated mechanically by using spring
2. Output shaft (3) to apply brake to output shaft (2) of the trans-
3. Spring mission.
4. Piston q The braking operation is made by pressing disc
5. Disc (5) and plate (6) with piston (4) by using the ten-
6. Plate sion of spring (3). By the operation output shaft
7. Front coupling (2) stops.
q The brake is released with piston (4) moved by
supplying pressurized oil into piston chamber A
and by overcoming the tension of spring (3) to
separate disc (5) and plate (6).
WA1200-6 10-123
Brake system
Parking brake solenoid valve
Parking brake solenoid valve 10-124
1. Solenoid valve assembly Outline 10-124

2. Block q By the operation of the parking brake switch to
turn it ON or OFF, the solenoid valve is ener-
B. Outlet port gized or de-energized. It leads the pressurized
P. Inlet port (from transmission) oil to the parking spring cylinder or cancels the
T. Drain port supply of the pressurized oil, that results the ma-
chine in the condition that the parking brake is
applied or not.
q Energizing the parking brake solenoid valve:
Traveling
De-energizing: Parking
10-124 WA1200-6
Brake system
Emergency parking brake release valve
Emergency parking brake release valve 10-125

Operation 10-125
q when the parking brake emergency release
switch (1) is turned ON solenoid valve (2) is ac-
tivated. The oil pressure stored in the accumula-
tor (3) flows from port P, and as the circuit is
changed by the pilot pressure, the pressurized
oil flows through port A into the parking brake to
release the parking brake.
1. Valve Ass’y
2. Solenoid valve
A: To parking brake
B: From parking brake solenoid valve
C. From transmission
T. Drain
P. From brake (accumulator circuit)
Function 10-125
q The emergency parking brake release valve is
installed between the transmission and brake
circuit. When the oil pressure cannot be supplied
from the transmission pump because of engine
failure, etc., this valve activates the solenoid of
parking brake release switch on the operator's
seat to flow the accumulator charge pressure in
the brake circuit into the parking brake cylinder.
WA1200-6 10-125
Brake system
Check valve of parking brake circuit
Check valve of parking brake circuit 10-126

Function 10-126
q When the transmission gear is shifted, a large a This locking of parking brake is only for a mo-
amount of oil flows into the clutch in the trans- ment and does not have any affect on the oper-
mission instantaneously and the oil pressure de- ation of the machine. The operator also finds no
creases in the parking brake circuit for a problem.
moment. q The check valve of parking brake circuit is in-
q When the parking brake oil pressure decreases stalled between the main transmission and park-
to the engagement pressure or less, the parking ing brake circuits and prevents the oil pressure
brake is engaged to lock the parking brake for a from decreasing for a moment in the parking
moment. brake circuit when shifting the transmission
gear.
1. Valve
2. Spring
3. Body
4. Adapter
5. Elbow
6. O-ring
7. O-ring
A: From main transmission circuit
B: To parking brake circuit
10-126 WA1200-6
Brake system
Operation 10-127
1. When parking brake is released (ON o OFF [Reference] Cracking pressure of check
operation) valve assembly for parking brake circuit: 9.4
q When the parking brake switch is turned kPa {0.096 kg/cm2}
OFF, the parking brake solenoid valve is en-
ergized, the drain circuit in the parking brake
spring cylinder closes, and the circuit which
leads oil pressure A in the main transmission
circuit to the parking brake spring cylinder
opens.
q Here, by using the differential pressure
(A>B) occurred between ports A and B,
valve (1) in the check valve Ass’y of the park-
ing brake circuit compresses spring (2) left-
ward and moves to open port C.
q When port C opens, oil pressure A in the
main transmission circuit is led through port
B and the parking brake circuit to the parking
brake spring cylinder and the parking brake
is released. 3. When shifting transmission gear (during
operation of machine) while parking brake is
released:
q When the transmission gear is shifted (during
operation of machine) while parking brake is
released, a large amount of oil flows into the
transmission clutch for a moment, so the oil
pressure A in the main transmission circuit
decreases for a moment.
q Here, the valve (1) in the check valve Ass’y of
the parking brake circuit is pressed rightward
by the differential pressure (A<B) between
ports A and B as well as by the tension of
spring (2) to close port C further and shut off
the parking brake circuit B and main trans-
mission circuit A.
2. While parking brake is released q Therefore, oil pressure B in the parking brake
q While the parking brake is released, the oil circuit is protected from the drop of oil pres-
pressures of ports A and B are equal to each sure A in the main transmission circuit.
other, valve (1) is pressed rightward by the
tension of spring (2) to close port C.
q When oil pressure B in the parking brake cir-
cuit decreases because of the leakage from
the parking brake spring cylinder, etc. and
the differential pressure (A>B) between ports
A and B increases to the cracking pressure
of check valve Ass’y in the parking brake cir-
cuit or higher, valve (1) compresses spring
(2) and moves leftward to open port C and oil
pressure A in the main transmission is led
through parking brake circuit B to the parking
brake spring cylinder so that the oil pressure
of port B becomes equal to that in port A.
q This always keeps the oil pressure in the
parking brake spring cylinder equal to that of
the main transmission circuit while the park-
ing brake is released.
WA1200-6 10-127
Brake system
4. When parking brake is activated (OFF o ON 5. When engine is stopped

operation) q When the engine is stopped, the supply of oil
q When the parking brake switch is turned ON, pressure A to the main transmission circuit is
the parking brake solenoid valve is ener- stopped.
gized, the circuit which leads oil pressure A in q As this time, port C is still closed and in park-
the main transmission circuit to the parking ing brake circuit B between the check valve
brake spring cylinder closes and the drain cir- Ass’y of the parking brake circuit and parking
cuit in the parking brake spring cylinder brake solenoid valve, the oil pressure is in the
opens. main transmission circuit A before the engine
q When the pressurized oil in the parking brake stoppage is kept.
spring cylinder is drained, the parking brake k When removing a hose in the parking
is activated by the parking brake spring force. brake circuit, be careful because the
q As the oil pressures of ports A and B in the oil pressure remains inside even when
check valve Ass’y of the parking brake circuit the engine is stopped. (Loosen the
are equal to each other, valve (1) is pressed hose fitting a little, fully release inter-
rightward by the tension of spring (2) to close nal oil pressure, and then disconnect
port C. the hose.)
10-128 WA1200-6
Undercarriage and frame
Axle mount
Undercarriage and frame 10-129

Axle mount 10-129
WA1200-6 10-129
Axle mount
1. Front frame Front axle

2. Rear frame q Because the front axle directly receives the force
3. Rear axle during the work, the front axle is directly fixed to
4. Front axle the front frame with tension bolts.
5. ROPS support
Rear axle
q The rear axle can be oscillated at its center so
that each tire can keep in touch with the ground
even when traveling on soft ground.
10-130 WA1200-6
Center hinge pin
Center hinge pin 10-131
1. Front frame 4. Front axle Outline 10-131

q The front frame and rear frame are connected
2. Rear frame 5. Upper hinge pin with each other through bearings by the center
3. Rear axle 6. Lower hinge pin hinge pins. And, the steering cylinders adjust the
right and left turning angles of front and rear
frames, that is a turning radius.
WA1200-6 10-131
Jack-up point
Jack-up point 10-132
1. Front frame Outline 10-132

(lower left of lift arm cylinder mount) q To jack up the machine replacing a wheel, attach
2. Front frame the jacks to the front frame (bottom of lift arm cyl-
(lower right of lift arm cylinder mount) inder mount), rear frame (bottom of center
3. Rear frame hinge), and bottom of rear bumper.
(lower left of center hinge) q The jack up point is not indicated in the Opera-
4. Rear frame tion and Maintenance Manual because it is dan-
(lower right of center hinge) gerous to jack up the machine unnecessarily.
5. Rear bumper
(lower left of rear bumper)
6. Rear bumper
(lower right of rear bumper)
10-132 WA1200-6
Hydraulic system
Hydraulic piping layout drawing
Hydraulic system 10-13

Hydraulic piping layout drawing 10-13
WA1200-6 10-133
Hydraulic system
Hydraulic piping layout drawing
1. Bucket cylinder Outline 10-134

2. EPC valve q The hydraulic system is composed of work
3. Work equipment control lever equipment and steering circuits, and the work
4. Work equipment pump equipment circuit controls the operation of the
4A. Work equipment pump 1 bucket (and attachment).
4B. Work equipment pump 2 q The oil in the hydraulic tank is sent through work
5. Switch pump equipment pumps (4A), (4B), switch pump (5),
6. Accumulator and the steering valve to three work equipment
7. Oil cooler valves (11). When respective spools for bucket
8. Steering pump and lift arm in the work equipment control valve
9. Transmission (with transfer) are in neutral, the oil passes through the drain
10. Lift arm cylinder circuit in the work equipment control valve and is
11. Work equipment valve (3 pcs) filtered by the filter in the hydraulic tank and re-
turns to the hydraulic tank.
q When work equipment control lever (3) is oper-
ated, EPC valve (2) in the proportional solenoid
valve controlled by the command current from
the controller activates the bucket or lift arm
spool to operate each spool of work equipment
control valve by using hydraulic pressure. The oil
flows from the work equipment control valve into
lift arm cylinder (10) or bucket cylinder (1) to
move the lift arm or bucket.
q The maximum pressure in the hydraulic circuit is
controlled by the relief valve in the work equip-
ment control valve, and the safety valve (with
suction) and unload valve are installed in the
bucket cylinder circuit for protecting the circuit.
q As an accumulator is installed in the circuit, the
lift arm can be lowered down to the ground even
when the engine is stopped.
q The hydraulic tank is pressurized sealed type
and has a breather with a relief valve. Also, pres-
sure is applied to the tank, negative pressure is
prevented, and the cavitation in the pump is pre-
vented.
q Also, a port is attached to the hydraulic tank for
applying pressure to the hydraulic tank by using
the pressurized air in order to bleed the air in the
pumps when the piston pump and pump relevant
pipe are reassembled after their removal.
10-134 WA1200-6
Hydraulic system
Work equipment control lever linkage
Work equipment control lever linkage 10-135
1. Bucket lever knob 9. R.H. console forward-reverse slide lever

2. Lift arm lever knob 10. Armrest adjustment lever
3. Kickdown switch 11. Armrest
4. Load meter cancel switch
5. Work equipment lock lever
6. Speed control ON/OFF switch
7. Load meter sub-total switch
8. Work equipment control lever
WA1200-6 10-135
Hydraulic system
Hydraulic tank
Hydraulic tank 10-136
1. Strainer Outline 10-136

2. Oil filler port q The oil sent into each cylinder through the work
3. Oil filler port strainer equipment control valve from the hydraulic tank
4. Filter bypass valve using the pump merges with oil from each part in
5. Filter the return circuit. A part of the oil is cooled by the
6. Breather oil cooler and filtered with the oil filter to return
7. Cleaner into the hydraulic tank.
8. Drain valve q This oil filter filters whole oil in the return circuit
from the work equipment control valve. When
A. Oil cooler return port the oil filter is clogged, the bypass valve is acti-
B. Steering oil return port vated to move the oil back directly to the tank
C. Loader oil return port and prevent the filter from being damaged. Also,
D. Emergency steering oil return port the bypass valve is activated when negative
E. Main suction port pressure is generated in the circuit.
F. Emergency steering oil suction port q Strainer (1) is installed in the suction port of the
G. PPC, PV control, cooling oil suction port hydraulic tank.
10-136 WA1200-6
Hydraulic system
Hydraulic tank
Operation of oil filter bypass valve 10-137

q When filter is clogged
Bypass valve (1) opens and the oil bypasses the
filter and returns to the tank.
Bypass valve set pressure: 125 kPa
{1.27 kg/cm2}
q When return circuit has negative pressure

Valve (2) as a whole rises to act as a check
valve.
Check valve set pressure: 25.5 kPa
{0.26 kg/cm2}
WA1200-6 10-137
Hydraulic system
Hydraulic tank
Breather 10-138
1. Body
2. Filter element
3. Poppet
4. Sleeve
Breather set pressure: 0.14 MPa {1.4 kg/cm2}
Function 10-138
q Preventing negative pressure in tank
As the tank is pressurized and sealed type, the
oil level lowers down in the hydraulic tank to
cause negative pressure in the tank. Here, the
pressure difference against the atmosphere
opens poppet (3) to let atmospheric pressure
into the tank. It prevents negative pressure from
being generated.
q Preventing pressure buildup in tank
When the circuit is in operation and the pressure
becomes the specified value or higher because
of the oil level increase due to the hydraulic
cylinder operation and temperature increase,
sleeve (4) is activated to release the pressure in
the hydraulic tank.
10-138 WA1200-6
Hydraulic system
Work equipment pump No.1
Work equipment pump No.1 10-139

Model: HPV160 + 160
q The work equipment pump No.1 has two vari-
able displacement swash plate type piston
pumps, and a servo valve is attached to the front
pump, and the servo and CO + NC valves are at-
tached to the rear pump.
P: Main pump pressure IN port 1. Front pump

PA1: Front pump discharge port 2. Front servo valve
PA2: Rear pump discharge port 3. Rear servo valve
PD11: Drain port 4. Rear CO+NC valve
PD21: Drain port 5. Rear pump
PES1: ES valve output pressure IN port
PSV: Servo source pressure supply port
WA1200-6 10-139
Hydraulic system
Work equipment pump No.1 (HPV160 + 160) 10-140
PSV1: Servo valve source pressure port PSV2: Servo valve source pressure port
PSV1A: Servo valve output port PSV2A: Servo valve output port
PSV1B: Servo valve output port PSV2B: Servo valve output port
10-140 WA1200-6
Hydraulic system
1. Front shaft 8. Front end cap 15. Rocker cam

2. Front cradle 9. Coupling 16. Rear case
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
WA1200-6 10-141
Hydraulic system
Servo valve (front) 10-142
P2: Main pump pressure IN port 1. Servo valve

PAC1: Servo actuator port
PDR: Servo valve drain OUT port
PPO: Servo source pressure IN port
10-142 WA1200-6
Hydraulic system
Servo valve, CO + NC valve Ass’y (rear) 10-143
P: Main pump pressure IN port 1. CO+NC valve

PAC1: Servo actuator port 2. Servo valve
PAC2: Servo actuator port 3. Plate
PECN: CO + NC valve output pressure port
PES: ES valve pressure pickup port
WA1200-6 10-143
Hydraulic system
1. Servo valve (rear) 10-14
P1I: Main pump pressure IN port PDR: CO + NC valve drain port

P1O: Main pump pressure OUT port PPO: Servo source pressure OUT port
P2I: Main pump pressure IN port PECN: CO + NC valve output pressure IN port
P2O: Main pump pressure OUT port
10-144 WA1200-6
Hydraulic system
Structure 10-145
1. Locknut 7. Pin 13. Sleeve

2. Cover 8. Piston 14. Piston
3. Plug 9. Locknut 15. Spring
4. Spring 10. Plug 16. Plug
5. Valve body 11. Locknut 17. Cover
6. Arm 12. Cover 18. Locknut
Function 10-145
q The deliveries Q1 and Q2 of main pumps P1 and
P2 are controlled individually by respective ser-
vo valves.
As for the relation between pump delivery Q and
input signal PECN to servo valve is shown in the
graph on the right, Q increases or decreases in
proportion to PECN.
WA1200-6 10-145
Hydraulic system
1) Operation to increase pump delivery (angle increases) 10-146
Operation 10-146
q Control pump pressure PPO is led to port a. q At the same time, port a connects to port h and
q Signal pressure PECN from NC valve is led pressurized oil flows through port i into servo pis-
through port b into chamber c. ton chamber j to push servo piston (19) to the
q When signal pressure PECN increases, the right, so the swash plate angle of the main pump
pressure of chamber c pushes piston (8) to the increases and the pump delivery also increases.
right where the force of spring (4) balances. q As servo piston (19) moves, arm (6) turns
q At the same time, similar to piston (8), arm (6) around pin (7) in the counterclockwise direction
oscillates rightward around servo piston (19) as to move guide spool (13) to the left. Then, ports
a fulcrum to move guide spool (13) to the right. a, d, and h are closed, so delivery increases ac-
q As guide spool (13) moves, ports a and d are cording to signal pressure PECN.
closed. Furthermore, port d connects to drain
chamber e. This also connects servo piston
chamber f to drain chamber e via ports g and d.
10-146 WA1200-6
Hydraulic system
2) Operation to decrease pump delivery (angle decreases) 10-147
Operation 10-147
q When signal pressure PECN decreases, piston q At the same time, port a connects to port d and
(8) moves to the left where the force of spring (4) the pressurized oil flows through port g into ser-
balances with the pressure of chamber c. vo piston chamber f to push servo piston (19) to
q At the same time, similar to piston (8), arm (6) the right, so the swash plate angle of the main
oscillates leftward around servo piston (19) as a pump decreases and the pump delivery also de-
fulcrum to move guide spool (13) to the left. creases.
q As guide spool (13) moves, ports a and h are q As servo piston (19) moves, arm (6) turns
closed. Furthermore, port h connects to drain around pin (7) in the clockwise direction to move
chamber e. This also connects servo piston guide spool (13) to the right. Then, ports a, d,
chamber j to drain chamber e via ports i and h. and h are closed, so the delivery decreases ac-
cording to signal pressure PECN.
WA1200-6 10-147
Hydraulic system
2. CO + NC valve (rear) 10-148
P2: Main pump pressure IN port

PDR: CO + NC valve drain OUT port
PECN: CO + NC valve output pressure OUT port
10-148 WA1200-6
Hydraulic system
CO valve NC valve
1. Cover 8. Cover
2. Sleeve 9. Sleeve
3. Piston 10. Piston
4. Spool 11. Spool
5. Spring 12. Spring
6. Seat 13. Cover
7. Plug
WA1200-6 10-149
Hydraulic system
3.CO valve 10-150
Function 10-150
q When a load increases and the main pump de- q The CO valve is controlled by balancing the sum
livery pressure increases and the pressure of main pump delivery pressure P and CO valve
comes close to the relief pressure during opera- output pressure PEC with a spring.
tion, the CO valve reduces the delivery and relief
loss by using its cutoff function.
1) When main pump delivery pressure is not more than relief pressure: 10-150
Operation 10-150
q Spool (4) is pressed downward by spring (3). As
a result, ports a and b are fully open and ES
valve output pressure PE of the work equipment
pump No.2 is equal to CO valve output pressure
PEC. This makes CO valve output pressure PEC
maximum and the main pump delivery becomes
maximum.
10-150 WA1200-6
Hydraulic system
2) When main pump delivery pressure comes close to relief pressure 10-151
Operation 10-151
q When a load increases and the main pump de-
livery pressure P comes close to the relief pres-
sure, the main pump delivery pressure P pushes
piston (5). At the same time, CO valve output
pressure PEC pushes piston (5) to move spool
(4) upward.
q As a result, the notch of the spool throttles the
flow from port a to port b to increase the opening
areas of ports b and c (drain port). Thus, CO
valve output pressure PEC decreases and the
main pump delivery becomes minimum.
WA1200-6 10-151
Hydraulic system
Model: HPV95 + 95 + SAL(2) 40

q The work equipment pump No.2 has two vari-
able displacement swash plate type piston
pumps, and the servo and CO + NC valves are
attached to the front pump and the servo, TVC
and ES valves and a cooling fan gear pump are
attached to rear pump.
10-152 WA1200-6
Hydraulic system
P1: Orifice upstream pressure IN port

P1N1: Front pump pressure IN port
P1N2: Rear pump delivery pressure IN port
P1N3: Front pump delivery pressure IN port
P2: Orifice downstream pressure IN port
PA1: Front pump discharge port
PA2: Rear pump discharge port
PAG: Gear pump discharge port
PD11: Drain port
PD21: Drain port
PESO: ES valve output pressure OUT port
PSG: Gear pump suction port
PSV: Servo source pressure supply port
1. Front pump
2. Rear pump
3. Cooling fan gear pump (SAL(2) 40)
4. Rear servo valve
5. TVC valve
6. Block
7. ES valve (Engine sensing)
8. CO+NC valve
9. Plate
10. Front servo valve
WA1200-6 10-153
Hydraulic system
Work equipment pump No.2 (HPV95 + 95) 10-154
PSV1: Servo valve source pressure port PSV2: Servo valve source pressure port
PSV1A: Servo valve output port PSV2A: Servo valve output port
PSV1B: Servo valve output port PSV2B: Servo valve output port
10-154 WA1200-6
Hydraulic system
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
WA1200-6 10-155
Hydraulic system
Servo valve, CO + NC valve Ass’y (front side) 10-156
P: Main pump pressure IN port 1. CO + NC valve

P2: Main pump pressure IN port 2. Servo valve
PAC1: Servo actuator port 3. Plate
PES: ES valve output port
10-156 WA1200-6
Hydraulic system
1. Servo valve (front) 10-157
P2: Main pump pressure OUT port q For information on the structure, function, and
PDR: CO + NC valve drain IN port operation, refer to the section "1. servo valve
PECN: CO + NC valve output pressure IN port (rear)".
WA1200-6 10-157
Hydraulic system
2. CO + NC valve (front) 10-158
P: Main pump pressure IN port

PDR: CO + NC valve drain OUT port
10-158 WA1200-6
Hydraulic system
CO valve NC valve
1. Cover 8. Cover
2. Sleeve 9. Sleeve
3. Piston 10. Piston
4. Spool 11. Spool
5. Spring 12. Spring
6. Seat 13. Cover
7. Plug
WA1200-6 10-159
Hydraulic system
CO valve 10-160
Function 10-160
q When a load increases and the main pump de- q The CO valve is controlled by balancing the sum
livery pressure increases and the pressure of main pump delivery pressure P and CO valve
comes close to the relief pressure during opera- output pressure PEC with a spring.
tion, the CO valve reduces the delivery and relief
loss by using its cutoff function.
1) Main pump delivery pressure is not more than relief pressure: 10-160
Operation 10-160
q Spool (4) is pressed downward by spring (3). As
a result, ports a and b are fully open and ES
valve output pressure PE is equal to CO valve
output pressure PEC. This makes CO valve out-
put pressure PEC maximum and the main pump
delivery becomes maximum.
10-160 WA1200-6
Hydraulic system
2) When main pump delivery pressure comes close to relief pressure 10-161
Operation 10-161
q When a load increases and the main pump de-
livery pressure P comes close to the relief pres-
sure, the main pump delivery pressure P pushes
piston (5). At the same time, CO valve output
pressure PEC pushes piston (5) to move spool
(4) upward.
q As a result, the notch of the spool throttles the
flow from port a to port b to increase the opening
areas of ports b and c (drain port). Thus, CO
valve output pressure PEC decreases and the
main pump delivery becomes minimum.
WA1200-6 10-161
Hydraulic system
Servo valve, TVC valve, ES valve Ass’y (rear) 10-162
P1: Main pump pressure IN port PPO: Servo source pressure IN port
P2: Main pump pressure IN port POR1: Orifice upstream pressure IN port
PAC1: Servo actuator port POR2: Orifice downstream pressure IN port
PDR: Servo valve drain OUT port 1. ES valve
PES: ES valve output pressure OUT port 2. Block
PECN: CO + NC valve output IN port 3. TVC valve
P1N1: Main pump pressure IN port 4. Servo valve
P1N2: Main pump pressure IN port 5. Connector
10-162 WA1200-6
Hydraulic system
1. Servo valve (rear) 10-163
P1: Main pump pressure OUT port PPO: Servo source pressure OUT port
P2: Main pump pressure OUT port PECN: CO + NC valve output pressure IN port
PDR: ES valve drain IN port
WA1200-6 10-163
Hydraulic system
Structure 10-164
1. Locknut 7. Pin 13. Sleeve

2. Cover 8. Piston 14. Piston
3. Plug 9. Locknut 15. Spring
4. Spring 10. Plug 16. Plug
5. Valve body 11. Locknut 17. Cover
6. Arm 12. Cover 18. Locknut
Function 10-164
q The deliveries Q1 and Q2 of main pumps P1 and
P2 are controlled individually by respective ser-
vo valves.
As the relation between pump delivery Q and
input signal PECN to servo valve is shown in the
graph on the right, Q increases or decreases in
proportion to PECN.
10-164 WA1200-6
Hydraulic system
1) Operation to increase pump delivery (angle increases) 10-165
Operation 10-165
q Signal pressure PI acts via port D on chamber E q As guide spool (12) moves, ports B and A con-
in the control piston part. Also, control pump nect to each other, control pump pressure PC
pressure PC is led to port B. flows into chamber F in servo piston (11) to push
q When PI increases, the oil pressure acting on servo piston (11) to the right. So, the swash plate
chamber E increases and control piston (9) angle of the main pump increases to increase
moves to the right until the force of spring (10) the delivery.
balances with the oil pressure of chamber E. q This makes arm (4) turn around pin (13) in the
q At the same time, arm (4) oscillates rightward counterclockwise direction to move guide spool
around servo piston (11) as a fulcrum to move (12) to the left. Then, ports B, A, and C are
guide spool (12) to the right. closed, so delivery increases according to signal
pressure PI.
WA1200-6 10-165
Hydraulic system
2) Operation to decrease pump delivery (angle decreases) 10-16
Operation 10-16
q When signal pressure PI decreases, piston (9) q At the same time, port B connects to port C and
moves to the left where the force of spring (10) the pressurized oil flows into servo piston cham-
balances with the pressure of chamber E. ber H to push servo piston (11) to the left along
q At the same time, similar to piston (9), arm (4) with the force of spring (14), so the swash plate
oscillates leftward around servo piston (11) as a angle of the main pump decreases and the pump
fulcrum to move guide spool (12) to the left. delivery also decreases.
q As guide spool (12) moves, ports B and A are q As servo piston (11) moves, arm (4) turns
closed. Furthermore, port A connects to drain around pin (13) in the clockwise direction to
chamber T. This also connects servo piston move guide spool (12) to the right. Then, ports B,
chamber F to drain chamber T via port A. C, and A are closed, so delivery decreases ac-
cording to signal pressure PI.
10-166 WA1200-6
Hydraulic system
2. TVC valve (rear) 10-167
PPO: Servo source pressure IN port 1. Spring 5. Sleeve

P1: Main pump pressure IN port 2. Spool 6. Piston
P2: Main pump pressure IN port 3. Piston 7. Body
PDR: TVC valve drain OUT port 4. Piston 8. Solenoid
PE: TVC valve output pressure OUT
port
WA1200-6 10-167
Hydraulic system
Function 10-168
q The command current from the controller ac- q When the emergency pump drive switch is
cording to the engine speed makes the pump de- turned ON, the pump delivery is controlled ac-
livery optimal. cording to the pump delivery pressure (load) by
the hydraulic sensing based on a certain pump
absorption torque.
1) When command current from controller is small 10-168
Operation 10-168
q The command current sent from the controller q In consequence, ports a and b are almost fully
moves solenoid push pin (9) to move spool (2). open and almost all pressurized oil from the con-
Spool (2) stops in the position where spring (1), trol pump is output as the TVC valve output pres-
push pin (9), and TVC valve output pressure sure PTVC. TVC valve output pressure PTVC
PTVC balance with the force acting on piston (3). increases and signal pressure PECN increases,
Here, the command current is small and the so the pump delivery increases.
force of push pin (9) is small, so spool (2)
balances at lower part.
10-168 WA1200-6
Hydraulic system
2) When command current from controller is large 10-169
Operation 10-169
q The command current sent from the controller q As a result, the flow from port a to port b is throt-
moves solenoid push pin (9) to move spool (2). tled to increase the opening areas of ports b and
Spool (2) stops in the position where spool (2) c (drain port). Thus, TVC valve output pressure
balances with spring (1). Here, the command PE decreases and signal pressure PECN de-
current is large and the force of push pin (9) is creases, so the pump delivery decreases.
large, so spool (2) balances at upper part.
WA1200-6 10-169
Hydraulic system
3) When the emergency pump drive switch is turned ON and pump load is small 10-170
Operation 10-170
q When the emergency pump drive switch is
turned ON, the command current increases, the
force of solenoid push pin (9) increases, and
spring (1) is compressed.
q As the main pump delivery pressures P1 and P2
are low, spring (1) pushes spool (2) downward.
As a result, control pump delivery pressure PPO
is equal to TVC valve output pressure PTVC in-
creases and the pump delivery increases.
10-170 WA1200-6
Hydraulic system
4) When the emergency pump drive switch is turned ON and pump load is large 10-171
Operation 10-171
q When main pump delivery pressure P1 (or P2)
increases, piston (4) or (6) moves spool (2) up-
ward. As a result, the notch of the spool throttles
the flow from port a to port b to increase the
opening areas of ports b and c (drain port).
Thus, TVC valve output pressure PTVC de-
creases and the pump delivery decreases.
WA1200-6 10-171
Hydraulic system
3. ES valve (rear) 10-172
PDR: ES valve drain OUT port

PE: Front and rear connection port for TVC valve
output pressure
PES: ES valve output pressure OUT port
10-172 WA1200-6
Hydraulic system
1. Cover 7. Cover
2. Plug 8. Sleeve
3. Rod 9. Piston
4. Plug 10. Spool
5. Nut 11. Cover
6. Screw
WA1200-6 10-173
Hydraulic system
Function 10-174
q The valve controls the delivery rate of the work q Until the pilot pressure reaches to the differential
equipment pump according to the change of en- pressure 0.37 MPa {3.8 kg/cm2}, the pump deliv-
gine speed. ery (delivery per rotation) increases in proportion
q The work equipment pump employs the variable to the increase of the differential pilot pressure,
capacity type piston pump in order to reduce the that is, in proportion to the increase of engine
oil pressure consumption in the low-speed range speed. When the differential pressure reaches
of the engine for attaining an energy saving, and
0.37 MPa {3.8 kg/cm2}, the pump delivery (deliv-
at the same time, to improve the engine acceler-
ery per rotation) becomes maximum.
ation performance from low-speed.
When differential pilot pressure is at point a
q Therefore, the delivery (delivery per rotation) is
or smaller
changed based on the engine speed by convert-
ing the engine speed into differential pressure by
using the differential pressure valve.
When differential pilot pressure is at point b

or larger
Operation 10-174
q The oil from the PPC pump is sent through differ-
ential pressure valve (1) to the EPC valve.
q The pilot pressure from port A in differential
pressure valve (1) is led via work equipment
pump cutoff solenoid valve (NC valve) (3) to ES
valve (2), and the pilot pressure is led from port
B to ES valve (2).
q The differential pressure of the pilot pressure in-
creases as the flow rate from PPC pump in-
creases, that is, the engine speed increases.
q When the differential pilot pressure reaches
point a (0.14 MPa {1.44 kg/cm2}), ES valve

starts to work to change the swash plate angle of
the pump through the servo valve and servo cyl-
inder.
q As the swash plate angle changes, the piston
stroke of the pump changes and the pump deliv-
ery (delivery per rotation when the differential pi-
lot pressure is at point b) changes.
10-174 WA1200-6
Hydraulic system
EPC valve (for work equipment)
EPC valve (for work equipment) 10-175
WA1200-6 10-175
Hydraulic system
EPC valve (for work equipment)
1. Body
2. Spool
3. Solenoid
4. Connector
C1: To bucket spool (dump side)

C2: To bucket spool (tilt side)
C3: To lift arm spool (up side)
C4: To lift arm spool (down side)
P: From PPC pump
T: Drain
Function 10-176
q When the work equipment lever is operated, the
EPC valve supplies the hydraulic pilot pressure
to the work equipment valve by using the propor-
tional solenoid valve controlled by the command
current from "work equipment & AJSS controller"
to activate the bucket or lift arm spool.
10-176 WA1200-6
Hydraulic system
Neutral cutoff solenoid valve (NC valve)
Neutral cutoff solenoid valve (NC valve) 10-17
1. Solenoid
2. Spool
3. Body
4. Spring
A. Port A (to the ES valve of work equipment pump
No.2)
P. Port P (to hydraulic tank)
T. Port T (From differential pressure regulating
valve)
WA1200-6 10-177
Hydraulic system
Neutral cutoff solenoid valve (NC valve)
Outline 10-178
The neutral cutoff solenoid valve (NC valve) is in-
stalled between the differential valve and ES valve
of work equipment pump No.2 to change the deliv-
ery of work equipment pumps No.1 and No.2 ac-
cording to the working condition.
a WA1200 has a energy saving circuit which,
when traveling is detected, reduces the pressure
loss in the hydraulic circuit and the fuel con-
sumption by reducing the pump flow rate sup-
plied to the work equipment circuit.
a When three conditions below are met, the NC
valve works to reduce the delivery of piston
pump.
q Speed range is F3
q Travel speed is not slower than 10 km/h
q Work equipment lever is in neutral
Operation 10-178
When solenoid valve (1) is activated, spool (2) in the
valve moves to connect ports P and A to each other
and shut off port T at the same time.
This changes the pressure of oil flown into the ES
valve of work equipment pump No.2 from high pres-
sure to low pressure and thus minimize the delivery
of work equipment pump.
10-178 WA1200-6
Hydraulic system
Relief valve
Relief valve 10-179
1. Main valve
2. Valve seat q When the pressures in ports A and B reach the
3. Pilot poppet set pressure of poppet spring, pilot poppet (3)
4. Spring opens and the oil pressure in port B is released
5. Adjustment screw through port D to port C to reduce the pressure
in port B.
Set pressure:
For PPC: 2.9 MPa {30 kg/cm2}
For pump control: 2.9 MPa {30 kg/cm2}
Function 10-179
1. Relief valve for PPC
q The relief valve for PPC is installed between
the PPC pump and EPC valve. When the
EPC valve does not work or when unusual
pressure occurs, this valve releases the oil
sent from the pump to prevent the pump and
circuit from damage. (Maximum pressure of
the circuit is set)
2. Relief valve for pump control q When the pressure in port B decreases, the ori-
q The relief valve for pump control is installed fice in main valve (1) causes differential pressure
between the pump for controlling main pump between ports A and B and the pressure of port
and the main pump. This relief valve relieves A opens main valve (1) to release the oil in port
the oil sent from the control pump to maintain A.
the pressure main pump control circuit at the
constant level.
Operation 10-179
q Port A is connected to the pump circuit, and port
C to the drain circuit. The oil goes through the or-
ifice in main valve (1) and port B is filled with the
oil. And, pilot poppet (3) keeps in touch with
valve seat (2).
WA1200-6 10-179
Hydraulic system
Accumulator (for EPC valve)
Accumulator (for EPC valve) 10-180

Operation 10-180
q When the work equipment valve is in neutral af-
ter the engine stops, chamber A in bladder (4)
(amount of nitrogen gas: 3,000 cc) is com-
pressed by chamber B.
q When EPC valve is operated, the hydraulic pres-
sure in chamber B becomes 2.9 MPa
{30 kg/cm2} or lower and the nitrogen gas pres-
sure in chamber A expands bladder (4).
Therefore, the oil flows into EPC valve to acti-
vate EPC valve and move the work equipment
valve.
a Operating pressure: 1.6 to 2.9 MPa {16 to
30 kg/cm2}
1. Cap 4. Bladder
2. Nut 5. Oil port
3. Body 6. Nut
q Type of gas: nitrogen gas (N2)
q Volume of gas: 3,000 cc
q Maximum operating pressure: 2.9 MPa
{30 kg/cm2}
q Minimum operating pressure: 1.6 MPa
2}
{16 kg/cm
Function 10-180
q The accumulator is installed between the PPC
pump and EPC valve and the nitrogen gas is
filled in the extensible bladder. The bladder
stores oil pressure by using its compressibility
and enables to operate the lift arm and bucket by
using hydraulic drift only even after the engine
stops.
10-180 WA1200-6
Hydraulic system
Work equipment control valve
Work equipment control valve 10-181
1. Main relief valve PA1: From C1 of EPC valve

2. Bucket spool return spring PA2: From C3 of EPC valve
3. Lift arm spool return spring PB1: From C2 of EPC valve
4. Lift arm spool PB2: From C4 of EPC valve
5. Bucket spool A1: To bucket cylinder bottom
6. Body A2: To lift arm cylinder bottom
7. Suction safety valve B1: To bucket cylinder rod side
8. Unload valve B2: To lift arm cylinder rod side
9. Float selector valve P: Pump port
PI: From C4 of EPC valve
T: Drain port
WA1200-6 10-181
Hydraulic system
Outline 10-182
q Three work equipment control valves are in- q In order to protect the circuit from unusual pres-
stalled because the pump flow rate is large. This sure, two safety valves (with suction) (7) are in-
controls the operation of bucket and attachment stalled to the bucket circuit.
in the hydraulic system and its circuit is a tandem Note that, of two safety valves, the one works as
circuit where a priority is given to the bucket cir- a relief valve and the other refills the oil shortage
cuit. The work equipment control valve activates as a suction valve.
the spools by using the oil pressure from EPC
valve.
q The oil from the pump enters port P and the relief
valve controls the maximum oil pressure. The oil
passes through the bypass circuit of bucket
spool (5) and lift arm spool (4), flows via port T
into the drain circuit, and returns through filter to
the tank. When the bucket and lift arm spools are
activated, the oil flows into the bucket and lift arm
cylinders respectively.
However, as it is a bucket priority circuit, when
operating the bucket spool, the lift arm does not
work even if lift arm spool is operated.
10-182 WA1200-6
Hydraulic system
Main relief valve 10-183
1. Valve q When the pump pressure reaches the relief

2. Piston pressure set by spring (5), poppet (4) opens, and
3. Piston spring the pressurized oil in chamber (C) is drained into
4. Poppet chamber (D).
5. Poppet spring q As poppet (4) opens, the flow occurs as
6. Plug with valve seat (A)o(C)o(D).
7. Sleeve
8. Adjustment screw
9. Locknut
Set pressure: 31.9 MPa {325 kg/cm2}
Function 10-183
q The relief valve is installed at the inlet of the work
equipment control valve. When the oil pressure
rises above the specified level, this valve drains
the oil into the hydraulic tank to limit the maxi-
mum pressure of the work equipment circuit and
protect the circuit.
Operation 10-183
q Port (A) is connected to the pump circuit and port q As the pressure drops in the flow of (A) to (C)
(B) is connected to the drain circuit. The pressur- through hollow hole (b) in piston (2), the pres-
ized oil in port (A) is led through hole (b) in piston sure of chamber (C) drops against port (A), and
(2) to port (C). valve (1) moves to the right.
q When the pressurized oil in port (A) is not more q And, the pressurized oil flows from port (A) to
than the relief set pressure, poppet (4) comes port (B) to control the maximum oil pressure and
into contact with the seat in plug (6) to shut off protect the circuit.
the flow from chamber (C) to the drain circuit, so
the pressures of oil in port (A) is equal to pres-
sures of oil in chamber (C).
q As d2 < d3, valve (1) keeps in touch with the left
side. The size of sectional area: d5 > d4 > d1 >
d3> d2
WA1200-6 10-183
Hydraulic system
Suction safety valve 10-184 Operation as a safety valve:

q Port A is connected to the cylinder circuit, and
port B is connected to the drain circuit. The pres-
surized oil in port A is led through a hole in piston
(3) to port C. As d2<d3, main valve (2) keeps in
touch with the left wall.
The size of sectional diameter (sectional areas):
d5>d4>d1>d3>d2
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve spring
8. Sleeve
9. Adjustment screw q When unusual pressure occurs in port A to reach
10. Locknut the set pressure of spring (6), poppet (5) opens
and the oil in chamber C is drained through
Set pressure: 33.8 MPa {345 kg/cm2} chamber D and circumference a of suction valve
(1).
Function 10-184
q When unusual pressure occurs due to some im-
pact on the cylinder, the unusual pressure is re-
leased through the safety valve to protect the
hydraulic equipment including the cylinder.
q When negative pressure occurs in the cylinder
circuit, the valve acts as a suction valve.
10-184 WA1200-6
Hydraulic system
q As poppet (5) opens, the pressure drops in Operation as a suction valve:

chamber C, and piston (3) moves rightward. Pis- q When the negative pressure occurs in the cylin-
ton (3) comes into contact with the end of poppet der circuit, port A is interconnected to chamber
(4), and the oil is drained through throttle b into C, so both pressures becomes negative.Port E
chamber D. is receiving tank pressure of port B, and the
pressure of suction valve (1) increases in propor-
tion to the area difference between d5 and d1
due to tank pressure of E.This increased pres-
sure compresses spring (7) to move suction
valve (1) to rightward.Thus, oil flows from port B
to port A to prevent occurring of negative pres-
sure at port A.
q As the pressure in chamber C is lower than the

pressure in port A, main valve (2) moves right-
ward and the oil flows from port A into port B to
prevent the occurrence of unusual pressure.
q Even if unusual pressure occurs, as the diame-
ter of the cross-section of suction valve (1) is
large, suction valve (1) does not work because of
d1<d4.
WA1200-6 10-185
Hydraulic system
Float selector valve and unload valve 10-186
Function 10-186 2. Float position 10-186

q There are float selector valve (2) and unload q As the lift arm lever in lower position is pushed
valve (3) in the work equipment valve. When the further the lever is put it in float position.
lift arm lever is put in the float position, float se- The position of lift arm spool (1) in the work
lector valve (2) detects it and starts to activate equipment valve is the same as the lower posi-
unload valve (3) to put the lift arm in the float po- tion.
sition. Since the oil pressure of port (A) becomes higher
than that of LOWER port, float selector valve (2)
Operation 10-186 moves rightward, then back pressure of unload
1. Lower position 10-186 valve (3) is drained.Accordingly, unload valve (3)
q The lift arm lever in the lower position is shown. opens and the lift arm becomes FLOAT state.
10-186 WA1200-6
Hydraulic system
3. Float position (ride over) 10-187 4. Float position (hydraulic drift) 10-187
q If the machine rolls back and the lift arm rises, q If the machine rolls back and the lift arm drops by
cylinder rod side becomes high pressure, then its own weight, cylinder bottom side becomes
oil flows through port (B) and drains through un- high pressure, then oil drains through port
load valve (3).Cylinder bottom side becomes (C).Cylinder rod side becomes vacuum and oil
vacuum and oil flows in through port (C). flows in through port (B).
WA1200-6 10-187
Hydraulic system
Operation in hydraulic circuit 10-18

Lift arm and bucket spool in neutral position 10-18
Operation 10-18
q The oil enters through the steering valve into port q The oil from the PPC pump enters through check
(A) and relief valve (11) regulates maximum oil valve (13) into port (L) in EPC valve. But, as the
pressure. lift arm and bucket lever are in neutral position,
q As bucket spool (1) is in neutral, the bypass cir- the oil returns from PPC relief valve (12) into hy-
cuit opens, the oil in port (A) flows through sur- draulic tank.
rounding area of the spool into port (B). As lift
arm spool (2) is also in neutral, the bypass circuit
opens and the oil in port (B) flows through sur-
rounding area of the spool into port (C) in the
drain circuit and returns through filter in the hy-
draulic tank.
10-188 WA1200-6
Hydraulic system
Lift arm spool in raise position 10-189
Operation 10-189
q When lift arm lever (3) is pulled, the oil flows from q On the other hand, the oil in the cylinder head re-
port (L) in EPC valve to ports (N) and (T). Also, turns from port (K) through drain port (C) to the
the oil in port (S) flows through port (M) into the tank. Consequently, the lift arm rises.
drain circuit. The pressurized oil in port (T) push-
es lift arm spool (2) to put it in raise position.
q The oil from steering valve goes through the by-
pass circuit in bucket spool (1) into the bypass
circuit in lift arm spool (2). As the bypass circuit
is closed by the spool, the oil pushes and opens
check valve (10). The oil flows through ports (H)
and (I) into the cylinder bottom.
WA1200-6 10-189
Hydraulic system
Lift arm spool in lower position 10-190
Operation 10-190
q When lift arm lever (3) is pushed, the oil flows
from port (L) in EPC valve to ports (M) and (S).
Also, the oil in port (T) flows into the drain circuit.
The pressurized oil in port (S) pushes down lift
arm spool (2) to put it in lower position.
q The oil from the steering valve goes through the
bypass circuit in bucket spool (1) into the bypass
circuit in lift arm spool (2). As the bypass circuit
is closed by the spool, the oil pushes and opens
check valve (10). The oil flows through ports (J)
and (K) into cylinder head.
q On the other hand, the oil in the cylinder bottom
returns from port (I) through drain port (C) to the
tank. Consequently, the lift arm goes down.
10-190 WA1200-6
Hydraulic system
Lift arm spool in float position 10-191
Operation 10-191
q When lift arm lever (3) is pushed into the float po- q Consequently, the oil in the cylinder head flows
sition, the pressurized oil in port (L) of the EPC through port (K) and unload valve (8) into the
valve flows into port (M) and ports (S) and (W) as drain circuit. The oil in the cylinder bottom flows
well. Also, the oil in port (T) flows into port (N). through ports (I) and (C) into the drain circuit.
q The pressurized oil in port (S) pushes down lift Hence, the lift arm is put in float condition.
arm spool (2) to put it in lower position.
q When the differential pressure occurs in ports
(W) and (X) which is not less than the specified
pressure, valve (7) moves to the right, ports (C1)
and (C) are connected to each other, and the oil
flows into the drain circuit. As port (C1) is con-
nected to the drain circuit, unload valve (8)
moves up to flow the oil from the pump into the
drain circuit.
WA1200-6 10-191
Hydraulic system
Bucket spool in dump position 10-192
Operation 10-192
q When bucket lever (4) is pushed, the oil in port
(L) of EPC valve flows from port (Q) to port (V).
Also, the oil in port (R) flows into the drain circuit.
The pressurized oil in port (V) puts bucket spool
(1) in dump position.
q As the bypass circuit is closed by bucket spool
(1), the oil from port (A) pushes and opens check
valve (10). The oil from check valve (10) flows
through ports (F) and (G) into the cylinder head.
q On the other hand, the oil in the cylinder bottom
returns from port (D) through drain port (C) to the
tank. Consequently, the bucket dumps.
10-192 WA1200-6
Hydraulic system
Bucket spool in tilt position 10-193
Operation 10-193
q When bucket lever (4) is pulled, the pressurized
oil in port (L) of EPC valve flows from port (P) to
port (R). Also, the oil in port (V) flows into the
drain circuit. The pressurized oil in port (R) puts
bucket spool (1) in the tilt position.
q As the bypass circuit is closed by bucket spool
(1), the oil from port (A) pushes and opens check
valve (10). The oil from check valve (10) flows
through ports (E) and (D) into the cylinder bot-
tom.
q On the other hand, the oil in the cylinder head re-
turns from port (G) through drain port (C) to the
tank. Consequently, the bucket tilts.
WA1200-6 10-193
Work equipment
Work equipment linkage
Work equipment 10-194

Work equipment linkage 10-194
1. Bucket 5. Lift arm

2. Bucket link 6. Lift arm cylinder
3. Bell crank 7. Tip tooth
4. Bucket cylinder 8. Sweeper wing
10-194 WA1200-6
Work equipment
a The drawing below shows the left side of the machine as an example.
a The length of collars differs between the inside and outside of the body. (cross-section D-D)
Outline 10-195
All linkage pins of the work equipment employ the oil
sealed type.
WA1200-6 10-195
Electrical system
Machine monitor system
Electrical system 10-196

Machine monitor system 10-196
Outline 10-196
q In the machine monitor system, controllers con-
nected to the network monitor the machine con-
dition using sensors installed to various parts of
the machine, and control the machine. Their
monitoring and control information is sent to the
machine monitor through the network and the
machine monitor displays the information and,
thus, the operator can understand conditions of
the machine.
q The machine monitor has two display modes;

the normal mode and service mode.
q The normal mode is to be used by the operator

usually. The major display items in this mode are
as follows.
1. Items displayed normally

q Meters (Speedometer or engine tachometer)
q Gauges (engine coolant temperature gauge,
torque converter oil temperature gauge, hy-
draulic oil temperature gauge, and fuel
gauge)
q Pilot lamps
q Service meter
Following items are displayed according to their

settings.
q Calculated weight by load meter
q Time
q Travel speed and engine speed to be dis-
played on character display
2. Initializing function
Use this function to return the settings of the
machine monitor to the factory default.
10-196 WA1200-6
Electrical system
WA1200-6 10-197
Electrical system
Machine monitor electric circuit diagram 10-198
10-198 WA1200-6
Electrical system
WA1200-6 10-199
Electrical system
Machine monitor 10-20
1. Auto/manual shift selection pilot lamp 16. Brake oil pressure caution lamp
2. Shift lever position pilot lamp (gear speed) 17. Engine oil pressure caution lamp
3. Shift lever position pilot lamp (travel direction) 18. Hydraulic oil level caution lamp
4. Torque converter oil temperature gauge 19. Engine oil level caution lamp
5. Torque converter oil temperature caution lamp 20. Engine coolant level caution lamp
6. Engine coolant temperature gauge 21. Transmission filter clogging caution lamp
7. Engine coolant temperature caution lamp 22. Air cleaner clogging caution lamp
8. Tachometer 23. Parking brake pilot lamp
8A. Travel speed or engine speed 24. Brake oil temperature caution lamp
8B. Display unit for travel speed or engine speed 25. WIF separator caution lamp
8C. Payload measured by load meter 26. Pre-lubrication pilot lamp
8D. Type of material set in load meter 27. Maintenance monitor
8E. Payload or target payload 28. Battery electrolyte level caution lamp
8F. Designation of payload or target payload 29. Battery charge level caution lamp
9. Turn signal pilot lamp (left) 30. Emergency steering "Inactive" pilot lamp
10. Turn signal pilot lamp (right) 31. Emergency steering at "Operation" pilot lamp
11. Hydraulic oil temperature caution lamp 32. Character display
12. Hydraulic oil temperature gauge 33. Auto-excavation pilot lamp
13. Fuel level caution lamp 34. Auto-greasing pilot lamp
14. Fuel gauge 35. AJSS pilot lamp
15. Centralized warning lamp 36. Economy operation indicator
37. Gear shift indicator
10-200 WA1200-6
Electrical system
1. Traction control dial 8. Main monitor illuminance control switch

2. Travel speed control dial (LED/LCD selection)
3. Travel speed LED 9. Main monitor illuminance control switch
4. Active working switch (illuminance increase or decrease)
5. Emergency flashing lamp switch 10. Load meter switch
6. Headlamp switch 11. Parking brake switch
7. Service meter display switch 12. Starting switch
WA1200-6 10-201
Electrical system
Monitor display item list

(*): The numbers indicated here correspond to the numbers shown in "Machine monitor". Be sure to check their positions and symbols.
Item No.
(*) indi- Night lighting Signal input cir-
LED color Operation during
cated in dimming cuit: Direct signal Display condition or operation specifi-
No. Item (when light- self-check Remarks
"Machin Enabled: q input or through cation
ing up) (at key ON)
e moni- Disabled: – CAN
tor"
q Uses all 4 digits for engine speed
For 2 seconds: display, but 0 (zero) is always
q
Fully lights up. CAN (transmis- displayed in unit's place.
1 Tachometer 8 – Back light
For 1 second: Fully sion controller) q Numeral value in unit's place of
color: White
goes out. engine speed is rounded to near-
est whole number.
Character dis- LCD
Upper: KOMATS
play Character:
Lower: No display
(Upper: Ser- Black q CAN (transmis-
2 32 Displayed at the
vice meter) Back- Back light sion controller)
center for 3 sec-
(Lower: Speed ground:
onds.
meter) Gray
q Lower limit: 50 °C
q Needle at horizontal position:
CAN (transmis-
Engine coolant Needle stays at 85 °C
q sion controller
3 temperature 6 – stop position q Red zone start point: 102 °C
Back light [Engine control-
gauge (fixed). q Upper limit: 135 °C
ler])
(Scale marks are spaced
uniformly.)
Torque con- Needle stays at 110 °C
q Monitor panel
4 verter oil tem- 4 – stop position q Red zone start point: 120 °C
Back light (sensor input)
perature gauge (fixed). q Upper limit: 135 °C
uniformly.)
q Lower limit: 0 %
q Upper limit: 100 %
Needle stays at
q Monitor panel (Scale marks are spaced
5 Fuel gauge 14 – stop position
Back light (sensor input) uniformly.)
(fixed).
(Caution lamp lights up when fuel
level is lower than start point.)
Hydraulic oil Needle stays at 85 °C
q Monitor panel
6 temperature 12 – stop position q Red zone start point: 105 °C
Back light (sensor input)
gauge (fixed). q Upper limit: 125 °C
uniformly.)
CAN (transmis-
Shift lever posi- For 2 seconds:
F: Green sion controller) q Lights up or goes out according
tion pilot lamp Fully lights up.
7 3 N: Orange q Signal filtering is to command from transmission
(travel direc- For 1 second: Fully
R: Green performed by controller.
tion) goes out.
monitor panel.
For 2 seconds:
Shift lever posi- q Lights up or goes out according
Fully lights up. CAN (transmis-
8 tion pilot lamp 2 Green q to command from transmission
For 1 second: Fully sion controller)
(gear speed) controller.
goes out.
For 2 seconds:
q q Actual gear speed is displayed
Gear shift indi- Fully lights up. CAN (transmis-
9 37 – Back light according to command from
cator For 1 second: Fully sion controller)
color: White transmission controller.
goes out.
q Lights up or goes out according
For 2 seconds: to command from transmission
Economy oper- Fully lights up. CAN (transmis- controller.
10 36 Green q
ation indicator For 1 second: Fully sion controller) q Normally goes out except during
goes out. self-check if this function is dis-
abled in option setting.
q Detection condition: CN–FC04
(pin 3) is OPEN and travel speed
For 2 seconds:
Emergency is 1 km/h or faster.
Fully lights up.
11 steering "Inac- 30 Green q Monitor panel q Detection time: 1 second
For 1 second: Fully
tive" pilot lamp q Reset condition: CN–FC04 (pin
goes out.
3) is CLOSE.
q Reset time: 1 second
For 2 seconds:
Auto/manual q Lights up or goes out according
Fully lights up. CAN (transmis-
12 shift selection 1 Green q to command from transmission
For 1 second: Fully sion controller)
pilot lamp controller.
goes out.
For 2 seconds: q CN–FC02 (pin 3) is OPEN:
Auto-greasing Fully lights up. Flashes.
13 34 Green q Monitor panel
pilot lamp For 1 second: Fully q CN–FC02 (pin 3) is CLOSE:
goes out. Lights up.
10-202 WA1200-6
Electrical system
Item No.
ing up) (at key ON)
tor"
q Lights up, goes out, /flashes (in-
terconnected buzzer (B)
sounds), or flashes (buzzer does
not sound) according to com-
mand from transmission control-
ler.
For 2 seconds: CAN (work equip-
q Work equipment controller com-
Fully lights up. ment controller)
14 AJSS pilot lamp 35 Green q mands to flash (via transmission
For 1 second: Fully CAN (transmis-
controller).
goes out. sion controller)
q Flashing has 2 patterns; accom-
panied with or without sounding
buzzer.
q Priority is as follows.
Flashing with buzzer sounding >
flashing > lighting up > going out
For 2 seconds:
Auto-excava- Fully lights up. CAN (work equip-
15 33 Green q to commands from work equip-
tion pilot lamp For 1 second: Fully ment controller)
ment controller.
goes out.
q Operates according to input sig-
For 2 seconds:
nal (CN-FC02 (pin 2): Starting
Pre-lubrication Fully lights up.
16 26 Orange q Monitor panel motor terminal C).
pilot lamp For 1 second: Fully
q OPEN: Goes out
goes out.
q CLOSE: Lights up
q Obtains information on mainte-
nance items from VHMS at key
ON, whose remaining time to
maintenance is;
1. Remaining time to maintenance
Z 0 hour
2. 0 hour < remaining time to main-
For 2 seconds:
tenance Z 30 hours
Maintenance Fully lights up. CAN
17 27 Red q q Lighting condition: Lights up for
monitor For 1 second: Fully (KOMTRAX Plus)
30 seconds after self-check and
goes out.
then goes out if any item meets
above condition 1.
q Flashing condition: Flashes for
30 seconds after self-check and
then goes out if no item meets
above condition 1 and any item
meets above condition 2.
For 2 seconds: q Flashes according to input sig-
Turn signal pilot
Fully lights up. nal.
18 lamp (left and 9, 10 Green q Monitor panel
For 1 second: Fully q OPEN: Goes out
right)
goes out. q CLOSE: Lights up
WA1200-6 10-203
Electrical system
Item No.
ing up) (at key ON)
tor"
For 2 seconds:
Monitor panel q Lights up or goes out according
Fully lights up.
Red q CAN to command from each control-
For 1 second: Fully
(each controller) ler.
goes out.
(Special 1)
q Detection condition: Engine run-
ning judgment is OFF and shift
lever is in F or R position.
q Detection time: 1 second
q Reset condition: Release from
detection condition
q Reset time: Immediate
q Operation: Centralized warning
lamp lights up and buzzer
sounds (B).
(Special 2)
q Detction condition. Engine run-
ning judgment is ON, parking
brake is ON (OPEN) and shift le-
Centralized
19 15 ver is in a position other than N.
warning lamp
q Detection time: Immediate
q Reset condition: Release from
detection condition
sounds (B).
(Special 3)
q Detection condition: Parking
brake emergency release switch
is "ON" (CN-FC03 (pin 4): GND).
q Detection time: Immediate
q Reset condition: Parking brake
emergency release switch is
"OFF" (CN-FC03 (pin 4): OPEN).
sounds (A).
Detection condition: CN–FC04 (pin 3)
Emergency For 2 seconds: is OPEN.
steering Fully lights up. Detection time: Immediate
20 31 Red q Monitor panel
"Active" pilot For 1 second: Fully Reset condition: CN–FC04 (pin 3) is
lamp goes out. CLOSE.
Reset time: Immediate
1. hen alternator voltage drops
q Detection condition: Alternator
voltage is 5 V or less, starting
motor terminal C signal is not in-
put, and engine running judg-
ment is ON.
q Detection time: 30 seconds
q Reset condition: 12 V or more
q Operation: this caution lamp
lights up, centralized warning
lamp lights up, buzzer sounds
(A), and failure code (AB00MA)
For 2 seconds: Monitor panel Alternator
Battery charge is displayed and recorded.
Fully lights up. (sensor input) voltage (see
21 level caution 29 Red q 2. When failure in charging circuit
For 1 second: Fully CAN (KOMTRAX the draw-
lamp occurs
goes out. Plus) ing.)
q Detection condition: Alternator
voltage is 12 V or higher when
engine is stopped.
q Reset condition: 5 V or less when
engine is stopped
q Operation: this caution lamp
lights up, and failure code
(AB00L6) is displayed and re-
corded.
3. When VHMS error (AB00MB)
occurs
For 2 seconds:
Battery electro-
Fully lights up. CAN q Lights up or goes out according
22 lyte level cau- 28 Red q
For 1 second: Fully (KOMTRAX Plus) to commands from VHMS.
tion lamp
goes out.
10-204 WA1200-6
Electrical system
Item No.
ing up) (at key ON)
tor"
For 2 seconds: q Lights up or goes out according
Parking brake Fully lights up. to input signal.
23 23 Red q Monitor panel
pilot lamp For 1 second: Fully q OPEN: Lights up.
goes out. q CLOSE: Goes out.
(Notice warning)
q Detection (reset) condition:
120 °C or more (less)
q Reset time: 5 seconds
q Operation: This caution lamp
lights up.
(Regular warning)
When following conditions (1) or (2)
are satisfied
(1)
q Detection condition: 130 °C or
more
q Reset condition: Less than
125 °C
For 2 seconds:
Brake oil tem- lights up, centralized warning
Fully lights up. Monitor panel
24 perature cau- 24 Red q lamp lights up, buzzer sounds
For 1 second: Fully (sensor input)
tion lamp (A), and failure code (B@C6NS)
goes out.
is displayed and recorded.
(2)
q Detection condition: 125 °C or
more
q Regular alarm is raised if travel
speed is 35 km/h or more after
the above conditions are satis-
fied (including the moment of sat-
isfaction).
q Reset condition: Less than
125 °C
(A), and failure code (B@C6NS)
is displayed and recorded.
WA1200-6 10-205
Electrical system
Item No.
ing up) (at key ON)
tor"
Condition (1): At key ON
q Detection condition: Brake oil
pressure drops (transmission
controller communication data).
q Reset condition: Brake oil pres-
sure returns to normal (transmis-
sion controller communication
data).
lights up.
Condition (2): Within 60 seconds after

engine running judgment ON after
key ON
Brake oil pressure returns to normal (transmis-
sure caution sion controller communication
For 2 seconds: CAN (transmis-
lamp data).
Fully lights up. sion controller)
25 (F and R brake 16 Red q Reset time: 1 second
For 1 second: Fully Judgment on the
oil pressure are q Operation: This caution lamp
goes out. monitor panel
sensed sepa- lights up, centralized warning
rately.) lamp lights up and buzzer
sounds (A).
Condition (3): 60 seconds or later

after engine running judgment
becomes ON

sure returns to normal (transmis-
sion controller communication
data).
(A), and failure code ([F]2G42ZG
or [R] 2G43ZG) is displayed and
recorded.
For 2 seconds:
Engine oil pres- to command from engine control-
Fully lights up. CAN (VHMS
26 sure caution 17 Red q ler.
For 1 second: Fully [ENG controller])
lamp q Lights up when engine controller
goes out.
generates failure code CA415.
For 2 seconds:
to command from engine control-
Engine oil level Fully lights up. CAN (VHMS
27 19 Red q ler.
caution lamp For 1 second: Fully [ENG controller])
q Lights up when engine controller
goes out.
generates failure code CA1544.
q Detection condition: SW (OPEN)
For 2 seconds: q Reset condition: SW (CLOSE)
Engine coolant
Fully lights up. Monitor panel q Reset time: 1 second
28 temperature 20 Red q
For 1 second: Fully (sensor input) q Operation: This caution lamp
caution lamp
goes out. lights up, and failure code
(B@BCZK) is displayed and re-
corded.
10-206 WA1200-6
Electrical system
Item No.
ing up) (at key ON)
tor"
q Detection condition: Engine run-
ning judgment is ON and monitor
input is OPEN.
q Reset condition: Monitor input is
GND.
For 2 seconds:
Air cleaner q Reset time: 1 second
Fully lights up. Monitor panel
29 clogging cau- 22 Red q q Operation: This caution lamp
For 1 second: Fully (sensor input)
tion lamp lights up, and failure code (*) is
goes out.
displayed and recorded.
(*)
din18: AA1ANX
din19: AA1BNX
din20: AA1CNX
din21: AA1DNX
(Failure detection)
q Detection condition: Engine is
stopped, and Din_24 is OPEN or
Din_34 is OPEN.
q Reset condition: Key at OFF po-
sition
q Operation: Failure code
(DHT2L6) is displayed and re-
corded.
For 2 seconds: (Clogging detection)

Transmission
Fully lights up. Monitor panel q Detection condition: Engine run-
30 filter clogging 21 Red q
For 1 second: Fully (sensor input) ning judgment is ON, Din_24 is
caution lamp
goes out. OPEN or Din_34 is OPEN,
torque converter oil temperature
is 50 °C or higher and above fail-
ure is not detected.
q Reset condition: Din_24 is
CLOSE and Din_34 is CLOSE.
lights up, and failure code
(15B0NX) is displayed and re-
corded.
q Detection condition: SW (OPEN)
For 2 seconds: q Reset condition: SW (CLOSE)
Hydraulic oil
Fully lights up. q Reset time: 1 second
31 level caution 18 Red q Monitor panel
For 1 second: Fully q Operation: This caution lamp
lamp
goes out. lights up and failure code
(B@HAZK) is displayed and re-
corded.
For 2 seconds: CAN (transmis-
WIF separator Fully lights up. sion controller
32 25 Red q to command from engine control-
caution lamp For 1 second: Fully [Engine control-
ler.
goes out. ler])
WA1200-6 10-207
Electrical system
Character display function 10-208

Use the character display to change the screed display and settings of the machine monitor.
For usage of functions available for the operator, see the Operation and Maintenance Manual.
The functions available for the operator are "Open-to-operator function" shown below.
1. Hierarchical structure
(*1) Once the ID input screen is skipped, the screen does not appear until the starting switch is turned to
OFF position, and it is allowed to move to the function selection screen.
10-208 WA1200-6
Electrical system
2. Flow of menu operation

Operations common to all screens
1) "Full blank" screen appears for 0.3 second
before each screen change (for notice of
screen change). The character display
remains full blank while waiting data.
2) While you are displaying a screen, if the
starting switch is turned to OFF position, the
screen (setting operation if you are in the
process of configuring settings) is regarded
as cancelled. The standard screen is
displayed on the character display next time
the starting switch is turned to ON position.
3) While you are in the service mode, the alarm
functions work as usual, but no caution is
displayed on the character display.
(The service functions can be used even if an
alarm is raised.)
After finishing the service functions, an alarm
display proper to the alarm item appears on
the screen if the alarm is raised.
4) The service functions can be used even
while the engine is running and the machine
is traveling.
(The service functions are not restricted
depending on the machine conditions.)
5) While the machine monitor is performing
CAN communications, no switch operation is
accepted until CAN communications is
finished. The character display remains full
blank.
(To prevent accumulation of S-NET commu-
nication requests caused by consecutive
switch operations.)
6) Display of switch mark U and t on the char-
acter display.
7) Mode switch operations are not accepted

while the self-check is performed.
WA1200-6 10-209
Electrical system
Open-to-operator functions 10-210 (*1): Service meter

Self-check (0th layer) q The service meter is indicated in a number
The self-check is performed for 3 seconds after the with six digits maximum including the number
starting switch is turned to ON position (key ON). of decimal places.
The self-check function starts automatically after q The upper digits remains blank before carry.
key ON. After the self-check is finished (after 3 sec- q The display positions of each digit of numeri-
onds), the character display automatically move to cal value and unit are fixed as shown in the
the 1st hierarchy. display example.
No mode switch operation is accepted during the (*2): Travel speed
self-check. q The unit of travel speed to be displayed is
that specified using the option setting func-
tion of the multi monitor.
Standard screen (1st layer)

The screen changes to the following screen display
automatically the after self-check.
10-210 WA1200-6
Electrical system
Load meter function 10-21 2) The calculated weight (payload) is indicated

1. Display and storage of load meter calculation above the bucket illustration to the right.
data a During "Display hold", load meter settings
such as Addition/Subtraction mode and
Materials cannot be changed.
(You cannot enter the load meter setting
screen.)
q Display holding time: 15 ± 2 seconds after
weight calculation stop is recognized
q Cancel of display (calculated weight): The
display of calculated weight is canceled in
the following cases.
When operating the cancel switch during
display holding time, or turning the
starting switch to OFF position or when
next weight calculation W1 is finished
q The indication of the weight display
changes to "0 (ton)" after the cancellation
1) The data is displayed on the above dedicated
or finish of the display holding time.
LCD.
q Display unit: ton (SI unit)
If "Non-display" is selected for the load meter
: To change the unit to short ton,
display by using the multi-monitor setting
select ST (short ton) in the unit
function, nothing is displayed on the load
setting screen (available only
meter related display area.
when ENGLISH is selected for
q At addition mode setting = TOTAL LOAD-
language).
ED lights up.
q Flashing of display: The weight display
At subtraction mode setting =
blinks (at 2 Hz) if the equality W = W1
REMAINING TARGET lights up.
holds for the calculation of weight W.
For materials, any one of A to E which are
q Display unit selection and details of data
assigned to type of material in advance
conversion for display output:
lights up.
All the internal data is based on SI unit
For selection of materials and modes, see
(MT: metric ton) and the internal data is
"Character display load meter".
converted into the value expressed in the
q Weight display: The indications of TOTAL
selected unit for the indication on the
LOADED and TARGET LOADED display
LCD. When On-load calibration is
areas are as follows.
performed, a value expressed in the
selected unit (if Short ton is selected) is
Actual weight Display input, and then the value is converted into
Below -9999 -9999 Displayed in
the value expressed in Metric ton to
integer num-
ber
rewrite the data. The data displayed in the
-9999–-1 -**** Displayed in real time monitor is expressed only in SI
integer num- units.
ber q Number of display digits: Integer (0 to
099999 ***** Displayed in 999)
integer num- q For the weight calculation, following cal-
ber culation formula is additionally applied to
Above 99999 99999 Displayed in correct the value obtained from the aver-
integer num-
age lift arm cylinder differential pressure
ber
that are measured every one second.
WA1200-6 10-211
Electrical system
press_dt = (press_dt – η) + (BA x α + ENG x β + HYD x 3) Cancel operation:

γ + BS x δ + PH x ε + ξ) q When the cancel switch is pressed during
the display holding time of the calculated
press_dt = Lift arm cylinder bot-
: Unit [MPa] weight, the load of the calculated weight
tom-head differential pressure
BA = Lift arm angle = ang_ avr (aver- is regarded as not loaded and the calcu-
: Unit [ deg.] lated weight data is discarded.
age lift arm angle)
ENG = Engine speed = eng_speed : Unit [rpm] q In this case, both of the Total loaded
HYD = Hydraulic oil temperature = weight (or remaining target weight) and
: Unit [ °C]
hyd_temp the addition (or subtraction) value calcu-
BS = Lift arm angular velocity = lated this time are cancelled and return to
: Unit [ deg.]
boom_ang-ang_avr
their previous values.
PH = Lift arm cylinder head pressure
= ph
: Unit [MPa] 4) The total loaded weight (or remaining target
α = Correction factor for lift arm weight) is indicated above the dump body
: Unit [MPa/ deg.] illustration to the left.
angle
β = Correction factor for engine 1] Display items in addition mode
: Unit [MPa/rpm]
speed q The measured weight is added and
γ = Correction factor for hydraulic oil resultant total weight is displayed. For
: Unit [MPa/ °C]
temperature the addition display and data saving,
δ = Correction factor for lift arm see the following.
: Unit [MPa/ deg.]
angular velocity
Calculation for one loading: Only the
ε = Correction factor for lift arm cylin-
: Unit [MPa/MPa] calculation result is indicated.
der head pressure
ξ = Intercept : Unit [MPa] When the display of calculated
weight is cleared (at the end of 15
α : Unit [MPa/ deg.] seconds of cancel period with the
β : Unit [MPa/rpm]
cancel switch), the addition weight
γ : Unit [MPa/ °C]
δ : Unit [MPa/ deg.] is accepted.
ε : Unit [MPa/MPa] Cancel of displayed value (total
ξ : Unit [MPa] weight): Press the cancel switch.
Values are subject to the Total weight displayed after subtotal
data sheet. switch is pressed: Value of 0 (ton) is
The cylinder differential pressure displayed.
(press_dt) is corrected based on the a Reset operations of total weight data
cylinder differential pressure and the and subtotal weight data are not inter-
rising speed of the lift arm. Linear interpo- connected.
lation is applied except for the specified Display unit: ton (SI unit)
points. : To change the unit to short ton,
Values are subject to the data sheet. select ST (short ton) in the unit
η : Unit [MPa] setting screen (available only
when ENGLISH is selected for
language).
Calculation unit
Calculation weight is indicated in incre-
ments of 0.01 ton.
The calculation value is rounded to the
nearest whole number when it is dis-
played on the monitor.
(RTM is indicated in increments of 0.01
ton.)
2] Display items in subtraction mode
q Initial display: The set target weight is
displayed. If the target weight is not
set, the previous set value is dis-
played.
q Calculation in subtraction mode
10-212 WA1200-6
Electrical system
The measured weight is subtracted Remaining W = Remaining weight before

from the initial display value, and the resulting in a negative value
resultant weight is displayed. For the Negative W = Measurement weight when
subtraction display and data saving, resulting in a negative value
see the following. W1 = Next measurement weight after
Calculation for one loading: Only the negative result
calculation result is indicated. W2 = Next calculation weight after W1
Usually in the subtraction mode, In this case, the determined
when the display of calculated payload after negative weight is
weight is cleared (at the end of 15 given as Payload at negative W
seconds of cancel period with the measurement = Negative W - W1.
cancel switch), the subtraction Payload at W1 measurement = W1
weight is accepted. But if the resul- – W2.
tant target weight is a negative CASE 2: The remaining target weight
value, the weight is displayed as (display weight) calculated in CASE1 is a
follows. negative value.
The negative values can be The buzzer (B) sounds (in a tone
displayed up to "-9999 (ton)". for operational error) to warn that
If the resultant remaining target the target weight is reached.
weight is a negative value, the The buzzer does not stop sounding
negative value is displayed for until the subtotal switch is pressed.
three seconds, and then the CASE 3: In the case the weight display is
remaining target weight, that has not cancelled after the subtotal switch is
accepted before the negative pressed.
value is obtained, appears and The weight of the load in the bucket
blinks. is determined to be the remaining
(This is called new subtraction weight for the next loading, and the
mode.) measurement weight is used in the
As an exception, the load meter does next subtraction.
not enter the new subtraction mode if CASE 4: In the case the weight display is
following conditions are satisfied. cancelled within 15 seconds after the
q In the case that the measured weight subtotal switch is pressed.
is 25.1 tons when the remaining target The load meter thinks that the
weight is 24.6 tons (displayed value is bucket is emptied and new loading
25 tons) is performed, and displays the
At this time, "-1t" is displayed above initial value for the remaining target
the dump body illustration, but the weight.
load meter does not enter the new q The symbol shown in the illustration is
subtraction mode. displayed on the multi monitor to warn
When the remaining target load reaches to the overloading (the buzzer sounds).
a negative value for the first time, the
buzzer sounds for five seconds and a cau-
tion mark to warn that the target weight is
reached is displayed.
(The buzzer sounds in the same tone as
that for operational error.)
(The caution mark to warn that the target
weight is reached is also displayed for five
seconds.) (Displayed on the multi-monitor)
CASE 1: The next weight measurement is
performed without any action.
In this case, the weight of the load
in the bucket is determined to be
the remaining weight that is not
loaded onto the dump truck.
Display weight = Remaining W - ((Nega-
tive W) - (W1 + W2 + …))
WA1200-6 10-213
Electrical system
5) Save and clear of subtotal data

Saving data: The following data items from
the previous loading to this loading are saved
as a unit (when the load data is accepted).
1] Type of material
2] Total loaded weight (displayed above the
dump body illustration)
q The subtotal data is cleared if the
switch is kept pressed for 2 seconds
or more.
(Only the data of material currently
selected is cleared.)
q When the clear is accepted, the buzz-
er beeps.
[Note] You must press the switch for 2
1. Material selector SW
seconds or more to accept the clear
2. Addition/subtraction selection switch
operation.
1) Display switching by using load meter selec-
6) Memory capacity:
tion switch
The total loading weight (weight displayed on
1] Switching material display
the dump body illustration) is updated and
q Each time the material selector switch
saved every time. Note that the data is saved
is pressed, the material display
material.
changes in turn as
AoBoCoDoEoAoBoCo····.
2. Change of calculation data display on load meter
q The material selector switch cannot
switch the calculation mode between
addition and subtraction modes.
q Switching material display does not
perform the subtotal function. (The to-
tal weight data is saved by material
even if the material selection is
changed.)
q Switching the material display does
not change the display on the
multi-monitor.
If the target value is not set as of material

change, the target setting screen is
displayed. (See 2] Addition/subtraction
q The load meter display can be switched by selection.)
using the load meter selector switch and from (The target value is already set, the target
the multi monitor. setting screen is not displayed.)
q If "No Load Meter" is selected for the load Pressing the material setting switch
meter setting in the Option Setting of the changes the display of the next material.
multi-monitor, the operations of material se- If the target is set, that material is
lection switch, addition/subtraction selection accepted for the display. if not, that mate-
switch, subtotal switch, and cancel switch are rial is not accepted until the target value
not accepted. input finishes.
Load meter selector switch The buzzer sounds (in confirmation tone)
at the time of material change. Note that it
is not allowed to change the material to
the one for which the target value is not
set.
10-214 WA1200-6
Electrical system
2] Switching calculation mode between 3] Others

addition and subtraction modes If the measurement starts during target
q Select the addition mode or the sub- value input, the screen returns to the
traction mode for each material. standard screen where the target value
q When subtraction mode is switched to becomes that for the material selected for
addition mode the last time. The buzzer beeps in cancel
The total weight (weight displayed tone (for 1 second).
above the dump body illustration) is If the input value is "0 t", the buzzer does
displayed while the subtraction target not sound because the message "Wrong
is saved. Setting" is displayed on the multi monitor.
The buzzer sounds (in confirmation When the target value is absent, the
tone) at this time. value displayed above the dump body
However, if returning to the addition illustration is "0 t" and that displayed on
mode while the target value is not set, the target value input screen is also "0 t".
the multi-monitor thinks that the target a For the details of target value setting
setting screen is cancelled and screen, see the section of "Multi mon-
sounds the buzzer (in cancel tone). itor".
q When addition mode is switched to
subtraction mode 3. Overload alarm
The multi-monitor screen moves to q If the value set in the service mode of the
the subtraction target input screen. multi monitor is exceeded, the following
Perform the following subtraction warnings are raised.
target input. (Set the subtraction 1) The display of load meter calculated weight
target on the multi-monitor.) (weight displayed above the bucket illustra-
q If "Addition/subtraction switch" is tion) blinks.
pressed again on the subtraction tar- 2) The overload alarm icon on the multi monitor
get input screen, the addition mode blinks.
continues and the buzzer sounds for 1 3) The special alarm buzzer for overload
second (in cancel tone). sounds.
q If the cancel switch is pressed on the q Resetting condition
subtraction target input screen, the These warnings continue for 5 seconds after
addition mode continues. detection of the overload, and then are reset
q When the confirmation switch is automatically.
pressed on the subtraction target in-
put screen with no target input, if no 4. Payload setting (setting of value for overload
target was input in the past, the mes- alarm)
sage "Wrong Setting" is displayed on Payload Setting screen
the multi monitor.
q When the confirmation switch is
pressed on the subtraction target in-
put screen, if any target value was in-
put in the past, the mode switches to
the subtraction mode.
q While the target setting screen is dis-
played, if the set target value is not yet
accepted, the buzzer does not sound
(in confirmation tone).
(Completion of the setting can be
known from the message "Setting
Completed" displayed on the multi
monitor when the target value setting
finishes.)
a The above switches "Cancel switch"
and "Confirmation switch" are the
switches used in the target weight set-
ting screen on the multi monitor.
WA1200-6 10-215
Electrical system
q When this screen (Payload Setting screen) is q Default

switched from the standard screen, the cur- The default for the value is "99 [t]", where no
rent payload set value is displayed. warning about overload is raised.
q The current set value is displayed according The payload set value currently displayed is
to the information from the main monitor. "---" accepted by pressing [F6], and the value is
is displayed for the value until the set value is notified to the main monitor.
sent from the main monitor. After the main monitor accepts the change,
q If the current setting value cannot be re- the screen returns to the Adjustment Menu
ceived from the main monitor for 10 seconds (Load Meter) screen.
or more, the screen moves to the abort After notification of the change to the main
screen. monitor, if reception notice is not sent from
q Pressing [F3] decrements the value by 1 [t]. the main monitor for 10 seconds or more, the
q Note that the switch operation is not accept- screen moves to the abort screen.
ed until the set value is sent from the main Note that switch operations are not accepted
monitor (during "---" display). until the set value is sent from the main
q Pressing [F4] increments the value by 1 [t]. monitor (during "---" display).
q Note that the switch operation is not accept- Pressing [F1] aborts the setting operation
ed until the set value is sent from the main and the screen returns to the Adjustment
monitor (during "---" display). Menu (Load Meter) screen.
q The numeric value must not exceed the up-
per and lower limits of the setting range.
q Numeric value setting range
Metric ton: 20 to 99 [t]
US ton: 22 to 99 [t]
Note that if "99 [t]" in metric ton or US ton is
set for the value, the monitor enters a mode
in which no warning is raised for any loaded
weight.
q When the display unit is switched be-
tween Metric ton and US ton, the set val-
ue before the change is saved and the
translated value expressed in the set ton
is displayed.
(example)
If "20 [t]" is set in metric ton and the unit is
changed to US ton, and if returning to the
numeric value setting screen again, the
value is changed to "22 [t]" in US ton that
is equal to "20 [t]" in metric ton.
10-216 WA1200-6
Electrical system
Abort screen of Payload Setting screen
The main monitor outputs the command to

the multi monitor for transition to this screen
at the abort, but the multi monitor
(KOMTRAX Plus) performs processing after
transition.
Pressing [F5] after confirmation of message
returns the screen to the Adjustment Menu
(Load Meter) screen.
Real-time monitor 10-217

q Using the real-time monitor function of the
multi-monitor, the status of input and output sig-
nals of the machine monitor can be checked.
q For the displayed items, see "Multi monitor", "3.
Service menu, 1) Real-time monitor".
WA1200-6 10-217
Electrical system
Machine monitor back side 10-218
10-218 WA1200-6
Electrical system
Signal table by connector 10-219

CN-FC01 (070-20 poles) I = Input O = Output
Pin No. Specifications I/O Group Form of use WA1200-6 Remarks
1 --- – – ---
Power supply for clearance +24 V power
2 I – ---
lamps supply
Power supply for clearance +24 V power
3 I – ---
lamps supply
+24 V contin-
NSW power supply
4 NSW power source (+24 V) I – uous power
(+24 V)
supply
+24 V continu-
NSW power supply
5 NSW power source (+24 V) I – ous power
(+24 V)
supply
+24 V power SW power supply (+24
6 SW power source (+24 V) I –
supply V)
+24 V power SW power supply (+24
7 SW power source (+24 V) I –
supply V)
8 --- – – ---
9 GND I – GND GND
10 GND I – GND GND
D_OUT_3
11 O A D/O sink ---
(+24 V, Sink 200 mA)
D_OUT_2
12 O A D/O sink ---
(+24 V, Sink 200 mA)
D_OUT_1
13 O A D/O sink Buzzer output 2
(+24 V, Sink 200 mA)
D_OUT_0
14 O A D/O sink Buzzer (output 1)
(+24 V, Sink 200 mA)
Sensor power supply output Sensor power Lift arm pressure
15 O –
(+24 V) supply sensor power supply
Sensor power supply output Sensor power Lift arm angle sensor
16 O –
(+5 V) supply power supply
WA1200-6 10-219
Electrical system
CN-FC02, CN-FC03 (070-18 poles + 12 poles) I = Input O = Output

CN-FC02
1 D_IN_0 (24 V, 5 mA) I B D/I, +24 V ---
2 D_IN_2 (24 V, 5 mA) I B D/I, +24 V IGNC
3 D_IN_4 (24 V, 5 mA) I B D/I, +24 V Auto-greasing input
4 D_IN_6 (24 V, 5 mA) I B D/I, +24 V ---
5 D_IN_8 (24 V, 5 mA) I B D/I, +24 V ---
Load meter material
6 D_IN_10 (24 V, 5 mA) I B D/I, +24 V
selector switch input
7 D_IN_12 (24 V, 5 mA) I C D/I, +24 V Right turn signal
To check SMR
with starting
8 D_IN_14 (NSW 24 V, 5 mA) I C D/I, +24 V Service meter switch
switch at OFF
position
9 GND O – GND
10 D_IN_1 (24 V, 5 mA) I B D/I, +24 V ---
11 D_IN_3 (24 V, 5 mA) I B D/I, +24 V ---
12 D_IN_5 (24 V, 5 mA) I B D/I, +24 V ---
13 D_IN_7 (24 V, 5 mA) I B D/I, +24 V ---
14 D_IN_9 (24 V, 5 mA) I B D/I, +24 V ---
Load meter ADDI-
TION/SUBTRACTION
15 D_IN_11 (24 V, 5 mA) I B D/I, +24 V
mode selector switch
input
16 D_IN_13 (24 V, 5 mA) I C D/I, +24 V Left turn signal
17 D_IN_15 (24 V, 5 mA) I C D/I, +24 V ---
18 A_IN_0 (0 to 30 V) I H A/I Alternator R
CN-FC03
1 D_IN_16 (24 V, 5 mA) I D D/IGND ---
2 D_IN_18 (24 V, 5 mA) I D D/IGND Air cleaner clogging 1
3 D_IN_20 (24 V/GND, 5 mA) I D D/IGND Air cleaner clogging 3
Parking brake emer-
4 D_IN_22 (24 V/GND, 5 mA) I D D/IGND
gency release signal
Transmission filter clog-
5 D_IN_24 (24 V/GND, 5 mA) I E D/IGND
ging 1
6 GND O – GND GND
7 D_IN_17 (24 V/GND, 5 mA) I D D/IGND ---
Illuminance adjustment 1
10 D_IN_23 (24 V/GND, 5 mA) I D D/IGND
switch input
Illuminance adjustment 2
11 D_IN_25 (24 V/GND, 5 mA) I E D/IGND
switch input
12 A_IN_1(0–30 V) I H A/I Clearance lamp switch
10-220 WA1200-6
Electrical system
CN-FC04, CN-FC05 (070-18 poles + 12 poles) I = Input O = Output

CN-FC04
D_IN_26 (24 V/GND, 5
1 I E D/IGND Parking brake switch
mA)
D_IN_28 (24 V/GND, 5
2 I E D/IGND Hydraulic oil level
mA)
Emergency steering oper-
D_IN_30 (24 V/GND, 5
3 I E D/IGND ation/normal
mA)
(common)
D_IN_32 (24 V/GND, 5
4 I F D/IGND Subtotal switch
mA)
D_IN_34 (24 V/GND, 5 Transmission filter clog-
5 I F D/IGND
mA) ging 2
D_IN_36 (24 V/GND, 5
6 I G D/IGND Service function 2
mA)
D_IN_38 (24 V/GND, 5
7 I G D/IGND < switch input
mA)
8 P_IN_0(0.5 Vp-p) I M P/I ---
9 GND O – GND GND
D_IN_27 (24 V/GND, 5
10 I E D/IGND Engine coolant level
mA)
D_IN_29 (24 V/GND, 5 Illuminance adjustment 3
11 I E D/IGND
mA) switch input
12 N.C. I E D/IGND ---
D_IN_33 (24 V/GND, 5
13 I F D/IGND Cancel switch
mA)
D_IN_35 (24 V/GND, 5
14 I F D/IGND U switch input
mA)
D_IN_37 (24 V/GND, 5
15 I G D/IGND > switch input
mA)
D_IN_39 (24 V/GND, 5
16 I G D/IGND t switch input
mA)
17 P_IN_1(.5 Vp-p) I M P/I ---
18 N.C. – – ---
CN-FC05
A_IN_2 (low resistance
1 I J A/I Fuel level sensor
input)
A_IN_4 (High resistance Torque converter oil tem-
2 I J A/I
input) perature sensor
A_IN_6 (High resistance
3 I K A/I ---
input)
Lift arm cylinder pressure
4 A_IN_8 (0 to 5 V) I L A/I sensor
(head)
5 A_IN_10 (0 to 14 V) – – ---
6 GND O – GND GND
A_IN_3 (High resistance Hydraulic oil temperature
7 I J A/I
input) sensor
A_IN_5 (High resistance Brake oil temperature
8 I J A/I
input) sensor
Lift arm cylinder pressure
9 A_IN_7 (0 to 5 V) I L A/I
sensor (bottom)
10 A_IN_9 (0 to 5 V) I L A/I Lift arm angle sensor
11 GND O – GND GND
12 A_IN_11 (0 to 14 V) – – ---
WA1200-6 10-221
Electrical system
CN-FC06 (070 12 poles) I = Input O = Output

1 S_NET (+) I/O N S-NET ---
2 S_NET (+) I/O N S-NET ---
3 CAN+ I/O P Communication (CAN (+))
4 S_NET (-) O N S-NET ---
5 S_NET (-) O N S-NET ---
6 GND O – GND ---
7 GND O – GND ---
8 CAN- I/O P Communication (CAN (–))
9 (NC) ---
10 (NC) ---
11 (NC) ---
12 (NC) ---
CN-FC07 (070 -14 poles) I = Input O = Output

1 (NC) – – ---
2 RS232C_1_RTS I/O Q ---
3 RS232C_1_RD I Q RD ---
4 (NC) I R RD ---
5 (NC) I/O R ---
6 – – ---
7 (NC) – – ---
8 RS232C_1_CTS I/O Q ---
9 RS232C_1_TX O Q TX ---
10 RS232C_1_SG O Q ---
11 (NC) O R ---
12 (NC) O R TX ---
13 (NC) I/O R ---
14 (NC) – – ---
10-222 WA1200-6
Electrical system
1
I = Input O = Output

Without harness con-
1 RS232C_0_TXD O S ---
nection
2 FLASH SW I S ---
nection
3 RS232C_0_TXD O S ---
nection
4 (NC) – – ---
nection
5 RS232C_0_RXD I S ---
nection
6 (NC) – – ---
nection
7 RS232C_0_RXD I S ---
nection
8 GND O – ---
nection
WA1200-6 10-223
Electrical system
Multi-function monitor
Multi-function monitor 10-2 4
Screen transition diagram 10-2 4
Outline 10-2 4
q The multi-function monitor allows for switching q The multi-function monitor has two display
the screen to the desired screens such as Main- modes; the normal mode for the operator in
tenance Monitor screen, User Settings screen, which the monitor usually stays, and the service
Productivity screen, Failure Message screen, mode for technicians in which they can check the
etc. by using function switches (F1 to F6) at the machine data, perform various settings of the
bottom of the screen. machine, and clear the machine data stored. (In-
q When an error occurs in the machine, the put of a dedicated ID is required.)
multi-function monitor automatically displays the a "Main Monitor" in the figure denotes the machine
warning screen. monitor.
10-224 WA1200-6
Electrical system
WA1200-6 10-225
Electrical system
1. Start screen, end screen, and alarm or error indication screen

1) When starting up multi-function monitor 2) When shutting down multi-function monitor
10-226 WA1200-6
Electrical system
3) When alarm or error is generated
WA1200-6 10-227
Electrical system
4) Special alarm (using icon) (*): Set bucket angle in the range from -5 to
q These alarm icons appear only in the +5 degrees (in increments of one degree)is
standard screen. indicated here.
q These special alarm icons follow usual
warning or error indications.
[1] Overload warning
This icon appear for five seconds
according to the command from the
machine monitor, and then disappears
automatically.
[2] Remaining target weight excess warning
This icon appears according to the
command from the machine monitor, and
disappears when the subtotal switch is
pressed.
[3] Transmission overrun protect

This icon appears and disappears
machine monitor.
q When direction protect conditions are
met
q When downshift protect conditions are
met
[4] Bucket positioner setting notice
This icon appears for three second
machine monitor, and then disappears
automatically.
10-228 WA1200-6
Electrical system
2. User menus
WA1200-6 10-229
Electrical system
1) Brightness and contrast, settings Night mode

q Use this menu to adjust the brightness,
contrast, and backlight of the multi-func-
tion monitor.
Adjust- Default Default
ment level (Day) (Night)
Brightness 1 to 7 4 2
Contrast 1 to 7 4 2
Backlight 1 to 10 10 1
q This menu allows for adjusting the bright-
ness, contrast, and backlight of the
multi-function monitor for each of the day
and night modes, and saving them.
Press [F1] to return to the standard
screen, applying the settings accepted
2) Consumption
before moving to this screen.
q Use this menu to displays the type of se-
Press [F2] to return the current settings of
lected materials, productivity (t/h) , and
brightness, contrast , and backlight to the
fuel consumption (L/h) for the specified
default values.
period, and the start and end dates of the
Press [F3] to reduce the level of the
calculation of them as well.
setting item highlighted.
q When the display setting of the load me-
Press [F4] to raise the level of the setting
ter is "Non-display", "----" is displayed for
item highlighted.
the Kind (of material) and Productivity,
Press [F5] to highlight the next setting
and only the value of Fuel Consumption
item.
and start and end dates are displayed.
(brightnessocontrastobacklightobright-
q Even if the selected kind of material is
ness...)
changed or the display setting of the load
Press [F6] to accept the settings made in
meter is switched between "Display" and
this screen and return to the standard
"Non-display", the calculated data is not
screen.
reset.
Day mode
screen.
Press [F2] to move to the PRODUC-
TIVITY HISTORY screen.
Consumption screen
10-230 WA1200-6
Electrical system
On this screen (PRODUCTIVITY HISTORY Deletion screen

screen) immediately after it is switched from
the standard screen, the material selected at
present is highlighted.
If the display setting of the load meter is
"Non-display", "----" is displayed for the Kind
(of material).
Press [F3] to highlight the immediate lower
material.
The materials are highlighted in order as
follows: AoBoCoDoEo"–"oA….
Press [F4] to highlight the immediate upper
material.
follows: Ao"–"oEoD oCoBoA….
3) User setting
Press [F6] to move to the deletion screen of
Press [F1] to return to the standard screen.
the highlighted material (including "–"). (See
Press [F3] to highlight the immediate lower
the deletion screen)
setting item.
Press [F1] to move back to the Consumption
When "Language" is highlighted, pressing
screen.
[F3] highlights "DATE".
Press [F4] to highlight the immediate upper
PRODUCTIVITY HISTORY screen
setting item.
When "DATE" is highlighted, pressing [F4]
highlights "Language".
Press [F6] to open the setting screen for the
menu item highlighted at present. (For more
information, refer to the description of the
setting screen.)
User setting screen
a The date shown on the above screen is

the date of previous exit.
When this deletion screen is displayed first,

only the information about the selected mate-
rial is displayed (highlighted).
Press [F2] to return to the PRODUCTIVITY
HISTORY screen without deleting the infor-
mation of the material.
a When "DATE" or "TIME", the screen
Press [F5] to reset (set to zero) the informa-
switches to the same DATA SETTING
tion (productivity data and fuel consumption
screen in either case.
data) of the material and set the date to
Note that the "year" data is highlighted on
blank, and to return to the Consumption
the DATE SETTING screen that is
screen.
opened by selecting "DATE". On the
DATE SETTING screen opened by
selecting "TIME", the "hour" data is high-
lighted.
WA1200-6 10-231
Electrical system
Date setting For the set value of "Daylight Saving

Press [F1] to return to the standard Time", if the current set value is "ON",
screen, applying the settings accepted pressing [F3] changes the highlighted
before moving to this screen. value to "OFF", or vice versa.
Press [F3] to advance the respective set The triangle mark that indicates the direc-
values (year, month, day, hour, and tion in which the currently highlighted
minute). value faces the non-highlighted value (in
The set value of year does not advance the figure, direction in which "OFF" faces
exceeding the upper limit. "ON") changes to the one that indicates
If the current set value of month is" Dec", the reverse direction.
it changes to "Jan". Press [F4] to turn back the numeric values
If the current set value of day is the last (year, month, day, hour, and minute).
day of the current set month ("Dec 31"), it The set value of year does not turn back
changes to the first day of the same exceeding the lower limit.
month ("Dec 1"). As for Daylight Saving Time, the change
If the current set value of hour is "23", it in the set value is the same as that when
changes to "0" (zero). pressing [F3].
If the current set value of minute is "59", it For the set values of other than "year" and
changes to "0" (zero). Daylight Saving Time when the set values
are respective lower limit, they change in
DATE SETTING screen (immediately after reverse to when pressing [F3].
being switched from previous screen by Press [F5] to highlight the immediate
selecting "DATE") lower setting item.
The setting items are highlighted in order
as follows: year omonthoday
ohourominuteodaylight saving timeo
year …
When entering the setting for Daylight
Saving Time, the marks shown above
switches [F3] and [F4] change from trian-
gles pointing to bottom and top to those
pointing to left and right respectively.
(See the DATE SETTING screen (for
setting of Daylight Saving Time) shown in
the following figure.)
Press [F6] to accept the current setting
and return to the User setting screen.
Note: If Janpanese is selected as the
DATE SETTING screen (immediately after
language, the daylight saving time cannot
being switched from previous screen by
be set.
selecting "TIME")
DATE SETTING screen (for setting of
Daylight Saving Time)
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Electrical system
User ID input USER ID SETTING screen

Any 10-digit number can be set for the
user ID.
When the user ID is changed, the alarm
and error indications that were cleared on
the alarm and error screens by pressing
the cancel button appear again if they are
active at the time of change of the user ID.
When this screen is displayed first,

numeral "1" is highlighted.
Press [F1] to return to the User setting
screen, applying the user ID accepted
Press [F2] to delete a number entered
last.
Language setting
If no number is entered, nothing is
When this screen is displayed first, the
changed on the screen.
current set language is highlighted.
Press [F3] to highlight a numeral on the
left of the currently selected numeral
screen, applying the language accepted
(highlighted).
If the currently highlighted numeral is "1",
Press [F3] to highlight the language
immediately under the currently high-
Press [F4] to highlight a numeral on the
lighted language.
right of the currently selected numeral
If the lowermost language is highlighted
(highlighted).
at present, the uppermost language is
If the currently highlighted numeral is "0",
highlighted.
Press [F4] to highlight the language
Press [F5] to select the currently high-
immediately above the currently high-
lighted numeral and input it in the entry.
lighted language.
(The numeral is input from the upper
If the uppermost language is highlighted
digit.)
at present, the lowermost language is
Press [F6] to accept the currently
highlighted.
displayed ID and return to the User setting
Press [F6] to accept the currently high-
screen.
lighted language and return to the User
setting screen.
WA1200-6 10-233
Electrical system
Language setting screen
a When the starting switch is turned to OFF

position, the current selection of the main
(Title display) screen is saved. When the starting switch
The screen title is displayed in English and is turned to ON position again, the main
the language names that are currently avail- screen is displayed according to the
able are expressed in respective languages. saved selection.
The titles are displayed as follows:
Available languages are expressed in Type and specification of main screen
"respective local languages" and the screen 1] Standard
title is expressed as "Language" Logo "KOMATSU" is displayed.
Main SCREEN select screen

current setting is highlighted.
screen, applying the setting accepted
Press [F3] to highlight the setting under
the currently highlighted setting.
If the lowermost setting is highlighted at
present, the uppermost setting is high-
lighted.
Press [F4] to highlight the setting immedi-
ately above the currently highlighted
setting.
If the uppermost setting is highlighted at
present, the lowermost setting is high-
lighted.
Press [F6] to accept the currently high-
lighted setting and return to the User
setting screen.
Main SCREEN Select screen
10-234 WA1200-6
Electrical system
2] Option 1
WA1200-6 10-235
Electrical system
a Each threshold value for working load and traveling load is the maximum value of the lighting
condition for the segment 20.
q Value after filtering = A x (previous value after filter) + (1 – A) x (A/D raw value)
A = exp (-2xfdt)
Where f indicates cutoff frequency and dt indicates a sampling time of 1.00.
Set value of working Set value of travel-
load ing load
A = 0.37 (f = 0.16 A = 0.37 (f = 0.16
[Hz]) [Hz])
(*): In order to avoid the phenomenon that all segments light up and go out instantaneously, the
lighting condition of all segments is regarded as not met if three pieces of data other than that
satisfy the lighting condition are counted (about three seconds).
(A1) The payload is determined based on the data received from the work equipment controller.
(A2) The engine load applied from drive side is determined based on the data received from
the transmission controller.
3] Option 2
This screen displays the total payload and total fuel consumption for every 30 minutes.
The data of total payload and total fuel consumption are received from KOMTRAX Plus.
Upper bar graph:

This bar graph indicates the total payloads [t] every 30 minutes for past 12 hours. (24 bars in total)
Data range: 0 to 2500 [t] (in increments of 1 [t])
Scale marks are placed up to 1500 [t] point at 500 [t] intervals, and scale marking is provided only at
the 1500 [t] point.
The bar can extend up to 2000 [t] that is higher than the top scale mark of 1500 [t] by one scale mark
interval of 500 [t]. Total payload exceeding 2000 [t] is displayed as a bar of 2000 [t].
The bar extends in increments of 50 [t].
The color of the bar depends on the total payload and changes as follows:
0 Z Total payload < 500: Blue
500 Z Total payload < 1000: Green
1000 Z Total payload < 1500: Orange
1500 Z Total payload: Red
10-236 WA1200-6
Electrical system
The cumulative sum is calculated only while the engine is running.

The calculation starts when the engine is started.
Then the data are summed up and recorded every 30 minutes and the bar graph is updated.
If the calculation of cumulative sum is stopped by turning the starting switch to OFF position, the data
obtained for the period after the previous saving until now (data for less than 30 minutes) is discarded.
This means that new calculation of cumulative sum starts when the engine is started again.
The default data for 24 data storage areas is "0" until the data is written.
The leftmost data is the data for the most recent 30 minutes, and right data is the data in the past.
When the 30 minutes go by and the data is recorded, the oldest data, the data 12 hours ago, is deleted.
Lower bar graph:

This bar graph indicates the total fuel consumptions [L] every 30 minutes for past 12 hours. (24 bars
in total)
Data range: 0 to 250 [L] (in increments of 1 [L])
Scale marks are placed up to 150 [L] point at 50 [L] intervals, and scale marking is provided only at 150
[L] point.
The bar can extend up to 200 [L] that is higher than the top scale mark of 150 [L] by one scale mark
interval of 50 [L]. Total fuel consumption exceeding 200 [L] is displayed as a bar of 200 [L].
The bar extends in increments of 5 [L].
The color of the bar depends on the total fuel consumption and changes as follows:
0 Z Total fuel consumption < 50: Green
50 Z Total fuel consumption < 100: Yellow
100 Z Total fuel consumption < 150: Orange
150 Z Total fuel consumption: Red
The cumulative sum is calculated only while the engine is running.

The calculation starts when the engine is started.
Then the data are summed up and recorded every 30 minutes and the bar graph is updated.
If the calculation of cumulative sum is stopped by turning the starting switch to OFF position, the data
obtained for the period after the previous saving until now (data for less than 30 minutes) is discarded.
This means that new calculation of cumulative sum starts when the engine is started again.
The default data for 24 data storage areas is "0" until the data is written.
The leftmost data is the data for the most recent 30 minutes, and right data is the data in the past.
When the 30 minutes go by and the data is recorded, the oldest data, the data 12 hours ago, is deleted.
WA1200-6 10-237
Electrical system
Data shown under the clock:

The biggest two total payload data are displayed from among 24 data currently recorded.
The smallest two total fuel consumption data are displayed from among 24 data currently recorded.
The biggest two efficiency data are displayed from among 24 data currently recorded.
(*) Efficiency = Total payload / Total fuel consumption
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Electrical system
4) Maintenance monitor (page 2)

q Use the MAINTENANCE MONITOR
screen to display the remaining time to
maintenance.
screen.
Press [F5] to move to the next page.
If you are in page 4, pressing [F5] moves
the screen to page 1.
Press [F2] to move to the previous page.
If you are in page 1, pressing [F2] moves
the screen to page 4.
Press [F3] to highlight the lower menu.
If the lowermost menu is highlighted,
pressing [F3] highlights the uppermost
menu.
(page 3)
Press [F4] to highlight the upper menu.
If the uppermost menu is highlighted,
pressing [F4] highlights the lowermost
menu.
Press [F6] to move to the maintenance
time reset screen for the menu high-
lighted at present.
Condition for highlighting the remaining

maintenance time
Yellow: The remaining maintenance time
is less than 30 hours.
Red: The remaining maintenance time is
less than 0 hour.
(page 1)
(page 4)
WA1200-6 10-239
Electrical system
On the maintenance time reset screen, press 6) Load meter menu

[F2] to return to the original screen without a "Main Monitor" in the figure denotes the
resetting the remaining maintenance time. machine monitor.
On the maintenance time reset screen, press The PRODUCTION SUMMARY screen
[F5] to reset the remaining maintenance time displays following productivity data by each
and return to the original screen. type of material (A to E) and the total.
1] Number of loading times
Maintenance time reset screen The number of loading weight data sent
from the main monitor after the previous
reset is counted and recorded.
2] Total loading weight
The loading weight data sent from the
main monitor after the previous reset are
summed up and recorded.
3] Last reset date
The last reset date is recorded.
When this screen (PRODUCTION

SUMMARY screen) is displayed first after it is
switched from the standard screen, the mate-
rial A is highlighted.
Press [F3] to highlight the lower material.
5) Failure message
follows: AoBoCoDoEoTOTALoA…
This screen displays the occurrent failures.
Press [F4] to highlight the upper material.
The serial number, 6-digit failure code, failure
details, and occurred time are displayed on
follows: AoTOTALoEoDoCoBoA…
the screen.
Press [F6] to move to the deletion screen for
The total number of failure occurrences is
the material (including TOTAL) highlighted at
displayed at the upper right.
present. (See the deletion screen.)
Press [F2] to move to the Load Meter Menu
Press [F2] to jump to the next page.
screen.
Press [F3] to scroll down the page by one
(See the Load Meter Menu screen.)
record.
Press [F4] to scroll up the page by one
PRODUCTION SUMMARY screen
record.
Press [F5] to jump to previous page.
FAILURE Message screen
10-240 WA1200-6
Electrical system
When this deletion screen is displayed first, Note: The menu of "Subtraction Mode Target
only the information about the selected mate- Setting" appears only when the subtrac-
rial is displayed (highlighted). tion mode is selected in the main monitor.
Press [F2] to return to the PRODUCTION The current set value is also displayed if
SUMMARY screen without deleting the the target is set. When it is not set yet, "0
material. t" is displayed for the value.
Press [F5] to reset (set to zero) the informa- When the mode is changed from the
tion (number of loading times, total loading subtraction to addition mode in the main
weight) of the material, to update the last monitor while the "Subtraction Mode
reset date, and to return to the PRODUC- Target Setting" is highlighted on this
TION SUMMARY screen. screen, the menu of "Subtraction Mode
Target Setting" disappears from the
Note: When this screen is displayed after screen and the uppermost menu of
selecting TOTAL, the information "No-Load Calibration" is highlighted.
(number of loading times and total loading When the kind of material to be applied to
weight) of all materials is reset (set to the subtraction mode is changed, the set
zero) and the last reset date is updated. value displayed on this screen is changed
(The last reset dates of the materials A to to that of the changed material type.
E and TOTAL become the same at this When "Non-display" is selected for the
point.) display setting of the load meter, the
menu configuration is the same as that for
Deletion screen the addition mode.
When this screen (Load Meter Menu screen)

is displayed first after it is switched from the
PRODUCTION SUMMARY screen, the
menu of No-Load calibration is highlighted.
pressing [F3] highlights the uppermost menu.
pressing [F4] highlights the lowermost menu.
Press [F1] to return to the PRODUCTION
SUMMARY screen.
Press [F6] to move to the execution screen of
the menu highlighted at present. (For more
screen.)
WA1200-6 10-241
Electrical system
Load Meter Menu screen After reading the message, press [F5] to
move to the Load Meter Menu screen.
Abort confirmation screen of No-Load Cali-

bration
*: The figure next to the menu of "On-Load

Calibration" represents the input value of
the reference weight for the previous
on-load calibration. When the on-load
calibration is not yet performed, "***" is
displayed for the value. b) On-Load Calibration
The allowable setting range of the refer- If this calibration ends successfully, the
ence load for the on-load calibration is screen returns to the Load Meter Menu
between 1.0 and 99.0 t and inputting the screen.
data out of the allowable setting range When this calibration aborts, the screen
moves the screen to the setting error moves to the abort confirmation screen.
screen. The main monitor issues the command to
a) No-Load Calibration move to next screen when the calibration
After moving to this screen, the screens are aborts. After the transition, the multi-function
switched sequentially according to the monitor (KOMTRAX Plus) performs the
commands from the main monitor. processing.
When this calibration ends successfully, the
screen returns to the Load Meter Menu Press [F1] to cancel the on-load calibration
screen. and move to the abort confirmation screen.
When this calibration aborts, the screen When the on-load calibration is canceled, the
moves to the abort confirmation screen. main monitor disregards the current calibra-
Press [F1] to cancel the no-load calibration tion result and revert the calibration data
and move to the abort confirmation screen. back to the original data.
When the no-load calibration is canceled, the
main monitor disregards the current calibra-
tion and revert the calibration data back to
the original data.
No-Load Calibration screen
10-242 WA1200-6
Electrical system
On-Load Calibration screen Load weight input screen
When this screen is displayed first, the initial *: Setting range: 1.0 to 99.0
load weight is displayed according to the
information from the main monitor. Press [F2] to return to the load weight input
The input place that is currently available is screen.
highlighted. When the load weight input screen is
The current input position is kept blank and displayed, the screen shows the same
no operation is accepted because of working numeric value in the input field as that on the
out the average of calibraion until the data is screen before moving to this load weight
received. confirmation screen, and highlights the fore-
most input place.
The input format is "**.* t". Press [F5] to accept the load weight entered.
Example: To input "5.3 t", enter "05.3". When the load weight is accepted, the
multi-function monitor informs the main
Press [F1] to move to the on-load calibration monitor of the load weight accepted.
cancel screen. The main monitor receives the accepted load
Press [F2] to move the highlighted input weight and informs the multi-function monitor
place to the left by one. of the reception. When the multi-function
If the foremost input place is highlighted, the monitor receives the notice, the screen
highlighted place does not move. moves to the setting completion screen.
Press [F3] to change the figure in the high- When the multi-function monitor determines
lighted place in the order of: that the main monitor did not set the load
9o8o7o6o5o4o3o2o1o0o9…. weight properly, the screen moves to the
Press [F4] to change the figure in the high- abort screen.
lighted place in the order of:
1o2o3o4o5o6o7o8o9o0o1…. Load weight confirmation screen
Press [F5] to move the highlighted input
place to the right by one.
If the last input place is highlighted, pressing
[F5] moves the screen to the load weight
confirmation screen.
(However, when the data is out of the setting
range, the screen displays the message
"Incorrect Setting" prompting re-entry.)
Press [F6] to return the input load weight to
the one that is informed from the main
monitor when this screen was switched from
the On-Load Calibration screen and to high-
light the foremost input place.

screen.
WA1200-6 10-243
Electrical system
Load weight confirmation screen (setting On-load calibration cancel screen

completion screen)
After reading the message, press [F5] to

This screen is the same as the load weight move to the Load Meter Menu screen.
input screen except that the message "Incor-
rect Setting" is displayed. Abort confirmation screen of on-load calibra-
tion
Load weight input screen (screen for warning
about incorrect setting and prompting
re-entry)
c) Calibration Reset
Press [F2] to return to the Load Meter Menu
screen without resetting the calibration.
Press [F2] to return to the load weight input Press [F5] to send the reset signal to the
screen. main monitor.
When the load weight input screen is The main monitor receives the reset signal
displayed, the screen shows the same and informs the multi-function monitor of the
numeric value in the input field as that sent reception. When the multi-function monitor
from the main monitor when this screen was receives the notice, the screen moves to the
switched from the On-Load Calibration setting completion screen.
screen, and highlights the foremost input
place. Note: When the calibration is reset, the data
Press [F5] to cancel the on-load calibration of both no-load and on-load calibrations is
result and return to the Load Meter Menu reset.
screen.
If the calibration is discontinued, the main
monitor ignores the calibration of this time.
10-244 WA1200-6
Electrical system
Calibration reset screen Load meter display setting selection screen
Press [F1] to move to the Load Meter Menu e) Subtraction Mode Target Setting
screen. When this screen is displayed first, the target
weight is displayed according to the informa-
Calibration reset screen tion from the main monitor.
(Setting completion screen) The input place that is currently available is
highlighted.
(When this screen is displayed first, the fore-
most place is highlighted.)
The current input position is kept blank and
no operation is accepted until the data is
received.
The input format is "**.* t".

Example: To input "350 t", enter "00350".

screen.
place to the left by one.
If the foremost input place is highlighted, the
d) Load Meter On/Off Selection
highlighted place does not move.
Press [F6] to send the notice of change in the
Press [F3] to change the figure in the high-
setting to the main monitor.
When the main monitor receives this change
9o8o7o6o5o4o3o2o1o0o9….
notice, the main monitor switches the display
setting of load meter between Display and
Non-display.
Even if the setting is changed, this screen
remains displayed.
Press [F1] to return to the Load Meter Menu
[F5] moves the screen to the setting comple-
screen.
tion screen.
(However, when the data is out of the setting
range, the screen displays the message
"Incorrect Setting" prompting re-entry.)
Press [F6] to return the input load weight to
the one that is sent from the main monitor
when this screen was switched from the
On-Load Calibration screen and to highlight
the foremost input place.
WA1200-6 10-245
Electrical system
Subtraction Mode Target Setting screen Subtraction Mode Target Setting screen
(setting completion screen)
*: Setting range: 1 to 99999

This screen is the same as the target weight
Operations to display the Subtraction Mode input screen except that the message "Incor-
Target Setting screen rect Setting" is displayed.
1] Selecting "Subtraction Mode Target
Setting" on the Load Meter Menu screen. Subtraction Mode Target Setting screen
2] Changing the mode of load meter from (screen for warning about incorrect setting
Addition to Subtraction by using the load and prompting re-entry)
meter switch on the main monitor.
Note that changing the mode from
Subtraction to Addition moves the screen
to the standard screen.
3] While in the subtraction mode, changing
the selected type of material to the one for
which the target weight is not set.
Conversely, if the selected type of mate-
rial is changed to the one for which the
subtraction target weight has been set,
the screen changes to the standard
screen.
Performing operations 2 and 3 shown above

does not display the Subtraction Mode
Press [F5] to move to the load meter menu
Target Setting screen in the following cases:
screen.
q When you are in the service mode
q When the maintenance time is reset, the
The main monitor issues the command to
productivity history is cleared, and the
move to this screen when the calibration
production summary is reset
aborts. After the transition, the multi-function
q When you are in the Load Meter Menu
monitor (KOMTRAX Plus) performs the
screen and subsequent screen
processing.
q When an emergency warning is displayed
(However, if all errors are cancelled, the
move to the Load Meter Menu screen.
screen is displayed.)
(This is common to all abort screens.)
Press [F1] to return the Load Meter Menu
screen.
10-246 WA1200-6
Electrical system
Abort screen for subtraction mode target

setting
a When the communication error with the

controller continues for 0.5 second or
more during the setting the target, the
screen returns to the standard screen
without going through the abort screen.
(This is common to all abort screens.)
WA1200-6 10-247
Electrical system
3. Service menu
How to enter into the service menu
(*1) If the ID is wrong, the screen does not change.

When this screen is displayed first, numeral "1" Use [F2] to delete the wrong ID and enter the
is highlighted. correct ID so that the screen moves to the
Press [F1] to return to the User setting screen. service menu screen.
Press [F2] to delete a figure entered last. Or, press [F1] to return to the User setting
When no figure entered, the screen display does screen, and then enter this screen again to input
not change. the correct ID.
Press [F3] to highlight the figure on the left of the
currently selected (highlighted) figure.
If the figurer "1" is highlighted at present, "0" is
highlighted.
Press [F4] to highlight the figure on the right of
the currently selected (highlighted) figure.
If the figurer "0" is highlighted at present, "1" is
highlighted.
Press [F5] to select the figure highlighted at
present and "*" is displayed for the figure in the
entry field. (The figures are input from the upper
digit.)
Press [F6] to accept the current ID displayed in
the entry field. If the input ID is correct, the
screen moves to the service menu screen.
10-248 WA1200-6
Electrical system
a Two types of ID are provided: the usual ID 1) Real time monitor

and special ID that allows for entering the When this screen (REAL TIME MONITOR
special optional menu. The entry of the spe- screen (for selection of controller)) is
cial ID allows you to enter the special optional displayed first, the menu item of Main Monitor
menu "Engine mode" in addition to the is highlighted.
menus that are allowed by entry of the usual Press [F3] to highlight the lower controller.
ID. If the lowermost controller is highlighted,
Service password: 7823401300 pressing [F3] highlights the uppermost
Special password: 3287040031 controller.
(*2) Press [F4] to highlight the upper controller.
When this screen (SERVICE MENU If the uppermost controller is highlighted,
SELECT screen) is displayed first, the menu pressing [F4] highlights the lowermost
item of Real Time Monitor is highlighted. controller.
Press [F3] to highlight the lower menu. (Scroll Press [F1] to move back to the SERVICE
function) MENU SELLECT screen.
If the lowermost menu is highlighted, Press [F6] to move to the REAL TIME
pressing [F3] highlights the uppermost menu. MONITOR screen of the controller high-
Press [F4] to highlight the upper menu. lighted at present. (For more information,
(Scroll function) refer to the description of the screen.)
pressing [F4] highlights the lowermost menu. REAL TIME MONITOR screen (for selection
Press [F1] to return to the standard screen. of controller)
Press [F6] to move to the execution screen of
the menu highlighted at present. (For more
screen.)
WA1200-6 10-249
Electrical system
Press [F1] to return to the REAL TIME As the engine has 16 cylinders, in order to
MONITOR screen (for selection of check the exhaust gas temperature of 16
controller). cylinders at the same time, a special screen
Press [F2] to move to the next page. " Exhaust gas temperature list" is provided.
Press [F5] to move to the previous page. If the menu of "6 ITEMS" is selected, desired
While "PAUSE" button is displayed, press cylinders can be specified (each cylinder has
[F3] to hold the values being displayed. an ID) to check the exhaust gas temperature
(The button indication changes to "RESET".) of individually. To check exhaust gas temper-
While "RESET" button is displayed, press ature of all cylinders at once, use the real
[F3] to release the values being held. time monitor function of the engine controller.
(The button indication changes to "PAUSE".)
For information on real time monitoring items
of each controller, refer to "Real time monitor
display items".
Each screen heading includes the controller

name to facilitate identification of controller
that is in charge of the current real time
monitor.
Real time monitor screen (main monitor,

transmission controller, work equipment
controller, engine controller, and KOMTRAX
Plus)
(Example of real time monitor screen of main
When this screen (REAL TIME MONITOR (6
monitor)
ITEMS) screen) is displayed first, the first row
is highlighted.
Press [F3] to highlight the lower row.
If the lowermost row is highlighted, pressing
[F3] highlights the uppermost row.
Press [F4] to highlight the upper row.
If the uppermost row is highlighted, pressing
[F4] highlights the lowermost row.
Press [F1] to return to the REAL TIME
MONITOR screen (for selection of
controller).
While "PAUSE" button is displayed, press
[F5] to hold the values being displayed.
(The button indication changes to "RESET".)
While "RESET" button is displayed, press
[F5] to release the values being held.
Press [F6] to move to the ID input screen for
the cylinder specified in the row highlighted
at present.
10-250 WA1200-6
Electrical system
6 ITEMS screen Press [F1] to cancel the ID entry and return to

the previous screen.
(The ID displayed on the previous screen is
value before moving to this screen.)
place to the left by one.
If the foremost place is highlighted, the high-
lighted place does not move.
[F5] does not move the highlighted place.
Press [F6] to accept the ID entry and return
to the previous screen.
ID input screen
The data is displayed only when the ID

entered has a corresponding monitoring
item.
If the ID entered has no corresponding moni-
toring item, only the ID entered is displayed.
The ID entered once is held in that place until
the starting switch is turned to OFF position
or the ID is changed.
A: When correct ID is entered

B: When wrong ID is entered
WA1200-6 10-251
Electrical system
Real time monitor display items

(*): Digits out of the display range are indicated as "-" (zeros, upper or lower limit values are not displayed).
Machine monitor
Monitor
Data Data display range
No. screen ID No. Item Remarks
unit (example)(*)
page
1 1 20200 MONITOR PROG P/N --- 10-digit part No. is displayed.
2 1 20221 VERSION(APP) --- 01010101
3 1 20222 VERSION(DATA) --- 01010101
Source: transmission
4 2 01001 ENGINE SPEED 1 rpm 0–4000
controller
5 2 40012 VEHICLE SPEED 0.1 km/h 0.0–50.0
6 2 04202 FUEL SENSOR 1% 0–100
7 2 04200 FUEL SENSOR 0.01V 0.0–5.0
Source: engine control-
8 2 04103 COOLANT TEMP 1 °C -40–210
ler
9 3 04408 T/C TEMP 1 °C 24–131
10 3 04409 T/C TEMP 0.01 V 0.00–5.00
11 3 04401 HYD. OIL TEMP 1 °C 24–131
12 3 04404 HYD. OIL TEMP 0.01 V 0.00–5.00
13 3 30201 BRAKE OIL TEMP 1 °C 24–131
14 3 30204 BRAKE OIL TEMP 0.01 V 0.00–5.00
15 4 04302 ALTERNATOR R 0.1 V 0.0–30.0
16 4 40200 SMALL LAMP 0.1 V 0.0–30.0
17 5 06001 BOOM ANGLE 1 deg. -90–90
18 5 06003 BOOM ANGLE 0.01 V 0.00–5.00
19 5 40400 BOOM BOTTOM PRESSURE 0.01 MPa 0.00–50.00
20 5 40402 BOOM BOTTOM PRESSURE 0.01 V 0.00–5.00
21 5 40500 BOOM HEAD PRESSURE 0.01 MPa 0.00–50.00
22 5 40501 BOOM HEAD PRESSURE 0.01 V 0.00–5.00
23 6 40600 CAL PRESSURE 0.01 MPa 0.00–50.00
24 6 40800 MEASURED LOAD 0.01 t 0.00–50.00
25 7 40900 D-IN 0-7 --- 01010101
26 7 40901 D-IN 8-15 --- 01010101
27 7 40902 D-IN 16-23 --- 01010101
28 7 40903 D-IN 24-31 --- 01010101
29 7 40904 D-IN 32-39 --- 01010101
30 7 40925 D-OUT 0-3 --- 01010101
10-252 WA1200-6
Electrical system
KOMTRAX Plus controller

Monitor
unit (example)(*)
page
1 1 37501 AMBIENT AIR TEMP 1 °C -30–100
2 1 37504 AMBIENT AIR TEMP 0.01 V 0.00–5.00
3 1 99701 PPC. OIL PRESSURE 0.01 MPa 0.00–50.00
4 1 99700 PPC. OIL PRESSURE 0.01 V 0.00–5.00
5 1 04304 Charged Amount 0.1 V 0.0–30.0
6 2 99703 T/M MAIN PRESSURE 0.01 MPa 0.00–50.00
7 2 99702 T/M MAIN PRESSURE 0.01 V 0.00–5.00
8 2 99705 T/M LUB PRESSURE 0.01 MPa 0.00–50.00
9 2 99704 T/M LUB PRESSURE 0.01 V 0.00–5.00
10 3 32601 T/C IN PRESSURE 0.01 MPa 0.00–50.00
11 3 32602 T/C IN PRESSURE 0.01 V 0.00–5.00
12 3 32603 TC OUT PRESSURE 0.01 MPa 0.00–50.00
13 3 32604 TC OUT PRESSURE 0.0 1V 0.00–5.00
14 3 29700 S/T PUMP PRESSURE 0.01 MPa 0.00–50.00
15 3 29701 S/T PUMP PRESSURE 0.01 V 0.00–5.00
F BRAKE OIL PRES-
16 4 92800 0.01 MPa 0.00–50.00
SURE
F BRAKE OIL PRES-
17 4 92802 0.01 V 0.00–5.00
SURE
R BRAKE OIL PRES-
18 4 92801 0.01 MPa 0.00–50.00
SURE
R BRAKE OIL PRES-
19 4 92803 0.01 V 0.00–5.00
SURE
20 5 40303 BATTERY LEVEL 1 0.01 V 0.00–5.00
21 5 40304 BATTERY LEVEL 2 0.01 V 0.00–5.00
22 5 40305 BATTERY LEVEL 3 0.01 V 0.00–5.00
01010101 ["1" or "0" in the corre-
sponding digit (number)] Outputs the input signals
23 6 40944 D-IN 0-7 ---
1: input signal ON, 0: input signal intact of D_IN_0 to D_IN_7
OFF, unused part is also zero.
01010101 ["1" or "0" in the corre-
24 6 40945 D-IN 8-15 ---
010 ["1" or "0" in the corresponding
digit (number)] Outputs the input signals
25 6 40972 D-IN 16-18 ---
0101 ["1" or "0" in the correspond-
Outputs the output signals
ing digit (number)]
26 6 40948 D-OUT 0-3 --- intact of D_OUT_0 to
1: output signal ON, 0: output sig-
D_OUT_3
nal OFF, unused part is also zero.
ing digit (number)] Outputs the input signals
27 6 40947 D = SOL 0-3 ---
1: input signal ON, 0: input signal intact of SEL_0 to SEL_3
WA1200-6 10-253
Electrical system
Engine controller
Monitor
unit (example)(*)
page
1 1 01002 ENGINE SPEED 1 rpm 0–8031 CM850
2 1 04102 COOLANT TEMP 1 °C -273–1735 CM850
3 1 42700 ENGINE OIL TEMP 1 °C -40–210 CM850
4 1 36400 Common RAIL PRESSURE 0.01 MPa 0–250.00 CM850
5 1 42801 BLOW BY PRESSURE 0.01 kPa -250–251.99 CM850
6 1 36501 BOOST PRESSURE 1 kPa 0–500 CM850
7 2 37200 ENGINE OIL PRESSURE 1 kPa 0–1000 CM850
8 2 43800 ENGINE OIL LEVEL --- OK (normal), NG (defective) CM850
9 2 37400 ATMOSPHERE PRESSURE 1 kPa 0–125 CM850
10 2 37300 FUEL Consump 0.1 l/h 0.0–3212.8 CM850
11 3 – EXHAUST GUS TEMP 1 °C -273–1735 CM850
12 4 42614 Ave. 1 °C -273–1735 CM850
13 4 42615 EXHAUST GUS TEMP R AVERAGE 1 °C -273–1735 CM850
14 4 42616 EXHAUST GUS TEMP L AVERAGE 1 °C -273–1735 CM850
15 5 42617 EXHAUST GUS TEMP R1 1 °C -273–1735 CM850
23 7 42625 EXHAUST GUS TEMP L1 1 °C -273–1735 CM850
a In the REAL TIME MONITOR (ENG controller), the exhaust gas temperature list screen is available
specially.
q As this screen is special, it cannot be displayed in [6 ITEMS] menu screen.
10-254 WA1200-6
Electrical system
Transmission controller
Monitor
Data Data unit
details (and range)
page
Part number of mass production 10-digit number
1 1 20201 T/M PROG P/N
software (78**-**-****)
T/M VER- Software version (software logic According to the software
2 1 20223
SION(APP) part version) version
T/M VER- Software version (software data According to the software
3 1 20224
SION(DATA) part version) version
0: Torque curve H For WA1200, 1:
Engine mode for engine output
4 2 41600 ENGINE MODE 1: Torque curve M Torque curve M
control
2: Torque curve L is not used.
Mod/C SPEED: x1[min-1]
5 2 92502 Modulation clutch output speed
OUT (0–32767[min-1])
x1[min-1]
6 2 31400 T/M SPEED: OUT Transmission output shaft speed
(0–32767[min-1])
x1[min-1]
7 2 93900 TIRE FR SPEED Front left tire speed
(0–32767[min-1])
x1[min-1]
8 2 01008 ENGINE SPEED Engine speed
(0–32767[min-1])
T/M CUT OFF SET Reduced transmission cutoff set x0.001[MPa]
9 3 41203
PRESSURE pressure (IN pressure) (0–5[MPa])
T/M CUT OFF x0.001[MPa]
10 3 41201 Reduced brake oil pressure
PRESSURE (0–5[MPa])
T/M CUT OFF x0.001[V]
11 3 41202 Input voltage of brake pressure
PRESSURE (0–5[V])
x1[%]
12 3 93700 T/C SPEED RATIO Torque converter speed ratio
(0–100[%])
Transmission oil temperature x1[ °C]
13 4 93600 T/M OIL TEMP
(A_IN_1) (0–150[ °C])
Input voltage of transmission oil x1[mV]
14 4 93601 T/M OIL TEMP
temperature (A_IN_1) (0.00–5.00[V])
Transmission oil temperature x1[ °C]
15 4 93602 T/M OIL TEMP2
(A_IN_3) (0–150[ °C])
Input voltage of transmission oil x1[mV]
16 4 93603 T/M OIL TEMP2
temperature input (A_IN_3) (0.00–5.00[V])
Oil pressure equivalent to modula-
MOD/C PRES- x1[MPa]
17 4 92400 tion clutch pressure input
SURE (0.00–5.00[MPa])
(A_IN_7)
MOD/C PRES- Voltage value of modulation clutch x1[mV]
18 4 92401
SURE pressure input (A_IN_7) (0.00–5.00[V])
Because of
THROTTLE LOCK 0: RPM set switch OFF
19 5 95500 Status of input signal detection at ana-
A 1: PRM set switch ON
log port
0: PRM set auto-decelera-
Because of
THROTTLE LOCK tion switch OFF
B 1: PRM set auto-decelera-
log port
tion switch ON
THROTTLE LIMIT Command value for lower limit of x0.1[%]
21 5 44201
LO throttle position (0.0–100.0[%])
x1[%]
22 6 94000 TRACTION DIAL Set value of traction dial
(0–100[%])
Input voltage of set value from x1[mV]
23 6 94001 TRACTION DIAL
traction dial (0.00–5.00[V])
x1[km/h]
24 6 40014 SPEED DIAL Set value of speed control dial
(3–12[km/h])
Input voltage of set value from x1[mV]
25 6 40015 SPEED DIAL
speed control dial (0.00–5.00[V])
Current value of ECMV output x1[mA]
26 7 31602 ECMV 1 DIR
command to 1st clutch (0–1000[mA])
27 7 31603 ECMV 2 DIR
command to 2nd clutch (0–1000[mA])
28 7 31604 ECMV 3 DIR
command to 3rd clutch (0–1000[mA])
29 7 31608 ECMV F DIR
command to FWD clutch (0–1000[mA])
30 7 31606 ECMV R DIR
command to REV clutch (0–1000[mA])
WA1200-6 10-255
Electrical system
Monitor
Data Data unit
details (and range)
page
31 7 31640 ECMV MOD/C DIR
command to modulation clutch (0–1000[mA])
Fill time of 1st clutch (at last gear x0.01[sec]
32 8 41802 FILL TIME 1
shifting) (0 to 2.55 [sec], 0: no fill)
Fill time of 2nd clutch (at last gear x0.01[sec]
33 8 41803 FILL TIME 2
Fill time of 3rd clutch (at last gear x0.01[sec]
34 8 41804 FILL TIME 3
Fill time of FWD clutch (at last gear x0.01[sec]
35 8 41808 FILL TIME F
Fill time of REV clutch (at last gear x0.01[sec]
36 8 41806 FILL TIME R
1: ON, 0: OFF(OPEN)
37 9 40905 D-IN 0-7 Status of input signal
Corresponds to each bit
1: ON, 0: OFF(OPEN)
1: ON, 0: OFF(OPEN)
1: ON, 0: OFF(OPEN)
Fix to 0 for
1: ON, 0: OFF(OPEN)
41 9 40942 D-IN 32-39 Status of input signal unused ports 33
to 39.
ON/OFF output from SOL_OUT0
1: ON, 0: OFF(OPEN)
42 10 40949 D-OUT 0-7 to 7. '0' indicates that drive current
is output.
1: ON, 0: OFF(OPEN)
43 10 40950 D-OUT 8-15 to 11B. '0' indicates that drive cur-
rent is output.
to 3, SW_OUT0 to 1, and 1: ON, 0: OFF(OPEN)
44 10 40951 D-OUT 16-23
BATT_RY_OUT. '0' indicates that Corresponds to each bit
drive current is output.
11-digit number indicates
learning flags for clutches in
the following order:
[FFFRRR11123]
Learned: 1, Not learned: 0 11-bit data in
Status of trigger time initial learn- F, R, and 1st clutches have 3 order of
Trigger learning ing flag for each clutch flags depending on learning FFFRRR11123 is
45 11 94100
Flag conditions starting from the displayed on
[F, F, F, R, R, R, 1, 1, 1, 2, 3] left: engine speed Z 875 rpm, multi-function
875 to 1200 rpm, and monitor.
engine speed X 1200 rpm
Learning flags for 2nd and
3rd clutches do not depend
on engine speed.
ANGLE SEN- Inclination angle equivalent to x0.1[ deg.]
46 11 32900
SOR(FR) pitch angle sensor input (A_IN_9) (-25.0–25.0[ deg.])
ANGLE SEN- Voltage value of pitch angle sensor x1[mV]
47 11 32902
SOR(FR) input (A_IN_9) (0.00–5.00[V])
ANGLE SEN- Inclination angle equivalent to x0.1[ deg.]
48 11 32904
SOR(LR) pitch angle sensor input (A_IN_9) (-25.0–25.0[ deg.])
ANGLE SEN- Voltage value of pitch angle sensor x1[mV]
49 11 32905
SOR(LR) input (A_IN_9) (0.00–5.00[V])
Oil pressure value equivalent to
BRAKE OIL PRES- x1[MPa]
50 12 35500 brake oil pressure sensor input Value not filtered
SURE F (0.00–50.00[MPa])
(A_IN_15)
BRAKE OIL PRES- Voltage value of brake oil pressure x1[mV]
51 12 35504
SURE F sensor input (A_IN_15) (0.00–5.00[V])
BRAKE OIL PRES- x1[MPa]
SURE R (0.00–50.00[MPa])
(A_IN_16)
BRAKE OIL PRES- Voltage value of brake oil pressure x1[mV]
53 12 35505
SURE R sensor input (A_IN_16) (0.00–5.00[V])
10-256 WA1200-6
Electrical system
Work equipment controller
Moni-
tor Data Data unit
No. ID No. Item Remarks
screen details (and range)
page
Part number of mass produc- 10-digit number
1 1 20202 BBC PROG P/N
tion software (78**-**-****)
Software version (software According to software ver-
2 1 20225 BBC VERSION(APP)
logic part version) sion
3 1 20226 BBC VERSION(DATA)
data part version) sion
Command current value to lift x1[mA]
4 2 41900 RAISE EPC DIR 1
arm RAISE EPC (0–1000[mA])
arm RAISE EPC (0–1000[mA])
6 2 41901 LOWER EPC DIR 1
arm LOWER EPC (0–1000[mA])
arm LOWER EPC (0–1000[mA])
Command current value to x1[mA]
8 3 41902 TILT EPC DIR 1
bucket TILT EPC (0–1000[mA])
bucket TILT EPC (0–1000[mA])
10 3 41903 DUMP EPC DIR 1
bucket DUMP EPC (0–1000[mA])
bucket DUMP EPC (0–1000[mA])
Input voltage value from lift armx0.01[V]
12 4 42000 BOOM POT1
lever potentiometer 1 (0.00–5.00[V])
Input voltage value from lift armx0.01[V]
13 4 42001 BOOM POT2
Input voltage value from bucket x0.01[V]
14 4 42002 BUCKET POT1
Input voltage value from bucket x0.01[V]
x0.1[deg]
16 5 06002 BOOM ANGLE Calculated lift arm angle
(-60.0–+60.0[deg])
Input voltage value from lift arm x0.01[V]
17 5 06005 BOOM ANGLE
angle sensor potentiometer (0.00–5.00[V])
The number of lift arm lever
0 to 256000 (in increments
18 5 42100 BOOM LEVER operations expressed in incre-
of 1000 operations)
ments of 1000 operations
The number of bucket lever
19 5 42101 BUCKET LEVER operations expressed in incre-
of 1000 operations)
x1[cc/rev]
20 5 94600 PUMP FLOW Calculated pump delivery
(150–830[cc/rev])
AJSS lever angle equivalent to x0.1[deg]
21 6 94300 AJSS LEVER
AJSS lever potentiometer input (-60.0–+60.0[deg])
Input voltage value from AJSS x0.01[V]
lever potentiometer (0.00–5.00[V])
Frame angle equivalent to
x0.1[deg]
23 6 94400 FRAME ANGLE AJSS frame potentiometer
(-60.0–+60.0[deg])
input
Input voltage value from AJSS x0.01[V]
24 6 94401 FRAME ANGLE
frame potentiometer (0.00–5.00[V])
Command current to AJSS x1[mA]
25 6 41908 AJSS EPC DIR
EPC (0–1000[mA])
Reduced loader pump pres- x0.01[MPa]
26 7 94700 LO PUMP PRESSURE
sure (0–56.3[MPa])
Input voltage value of loader x0.001[V]
pump pressure (0–5[V])
BOOM BOTTOM Reduced lift arm cylinder bot- x0.01[MPa]
28 7 40401
PRESSURE tom pressure (0–50[MPa])
BOOM BOTTOM Input voltage value of lift arm x0.001[V]
29 7 40402
PRESSURE cylinder bottom pressure. (0–5[V])
Deviation between AJSS frame
x0.1[deg]
30 7 94800 S/T DEFLECTION potentiometer angle and AJSS
(0.0–+120.0[deg])
lever angle
WA1200-6 10-257
Electrical system
Moni-
tor Data Data unit
No. ID No. Item Remarks
screen details (and range)
page
Status of digging-in-progress 1: ON (when in digging oper-
31 7 94900 WORK FLAG
flag ation), 0: OFF
1: ON, 0: OFF(OPEN)
Applied to each bit
1: ON, 0: OFF(OPEN)
Applied to each bit
1: ON, 0: OFF(OPEN)
Applied to each bit
1: ON, 0: OFF(OPEN)
Applied to each bit
Input signals 33-39
without port are
1: ON, 0: OFF(OPEN)
36 8 40961 D-IN 32-39 Status of input signal fixed at 0 to simplify
Applied to each bit
communication
information.
ON/OFF output from
SOL_OUT0 to 7. 1: ON, 0: OFF(OPEN)
37 9 40952 D-OUT 0-7
'0' indicates that drive current is Applied to each bit
output.
ON/OFF output from
SOL_OUT8 to 11B. 1: ON, 0: OFF(OPEN)
38 9 40953 D-OUT 8-15
'0' indicates that drive current is Applied to each bit
output.
ON/OFF output from
SIG_OUT2 to 3, HSW_OUT0
1: ON, 0: OFF(OPEN)
39 9 40954 D-OUT 16-23 to 1, and BATT_RY_OUT
Applied to each bit
'0' indicates that drive current is
output.
10-258 WA1200-6
Electrical system
2) PM clinic PM clinic item

Press [F1] to return SERVICE MENU Sampling
Component
SELECT screen. Page Item name Unit
in charge of
time
Press [F2] to move to the previous page. detection
If current page is page 1, pressing [F2] ENGINE Engine con-
1/4 2 seconds rpm
SPEED troller
moves the screen to page 4.
ENGINE OIL Engine con-
Press [F5] to move to the next page. 1/4 2 seconds kPa
PRESSURE troller
If current page is page 4, pressing [F5] ENGINE OIL Engine con-
moves the screen to page 1. 1/4 2 seconds degC
TEMP troller
While "PAUSE" button is displayed, press COOLANT Engine con-
1/4 2 seconds degC
[F3] to hold the values being displayed. TEMP troller
(The button indication changes to "RESET".) ENGINE Engine con-
2/4 2 seconds rpm
While "RESET" button is displayed, press SPEED troller
BLOW-BY Engine con-
[F3] to release the values being held. 2/4 2 seconds kPa
PRESSURE troller
(The button indication changes to "PAUSE".) BOOST PRUS- Engine con-
For information on the items displayed in 2/4 2 seconds kPa
SURE troller
each page, refer to the table. EXH GAS
Engine con-
2/4 TEMPERA- 2 seconds degC
troller
PM-CLINIC MENU screen (page 1) TURE
AMBIENT AIR KOMTRAX
2/4 2 seconds degC
TEMP Plus
Common Rsil Engine con-
2/4 2 seconds MPa
Pressure troller
3/4 T/C TEMP 2 seconds degC Main moniter
T/C IN PRES- KOMTRAX
3/4 2 seconds MPa
SURE Plus
T/C OUT KOMTRAX
3/4 2 seconds MPa
PRESSURE Plus
T/M MAIN KOMTRAX
3/4 2 seconds MPa
PRESSURE Plus
T/M LUB KOMTRAX
3/4 2 seconds MPa
PRESSURE Plus
Transmis-
T/M MOD
3/4 2 seconds MPa sion control-
PRESSURE
ler
HYD. OIL Main
4/4 2 seconds °C
TEMP monitor
PPC. OIL KOMTRAX
4/4 2 seconds MPa
PRESSURE Plus
Work equip-
HYD.OIL
4/4 2 seconds MPa ment control-
PRESSURE
ler
S/T PUMP KOMTRAX
4/4 2 seconds MPa
PRESSURE Plus
F BRAKE OIL KOMTRAX
4/4 2 seconds MPa
PRESSURE Plus
R BRAKE OIL KOMTRAX
4/4 2 seconds MPa
PRESSURE Plus
WA1200-6 10-259
Electrical system
3) Failure history 4) Snapshot

This screen displays the failure history. Press [F1] to return the SERVICE MENU
On this screen, the serial number, 6-digit SELECT screen.
failure code, brief explanation of failure, the Press [F6] to move to the snapshot trigger
number of failure occurrence, and the date of confirmation screen.
first and last occurrences of detected failure
are displayed. SNAPSHOT TRIGGER screen
The total of failure records number is indi-
cated at the upper right of the screen.
Press [F1] to return the SERVICE MENU

SELECT screen.
Press [F2] to jump to the next screen.
The top row is highlighted on the page.
Press [F3] to highlight the lower row.
Press [F4] to highlight the upper row.
Press [F5] to jump to the previous page.
The top row is highlighted on the page.
Press [F6] to hide the failure record in the
selected row.
When a row is hidden once, the record is not
displayed again.
Press [F2] to return to the SNAPSHOT
(However, the record in KOMTRAX Plus is
TRIGGER screen.
held.)
Press [F5] to start the snapshot.
(The screen changes the snapshot execution
FAILURE HISTORY screen
screen.)
Snapshot trigger confirmation screen
10-260 WA1200-6
Electrical system
Press [F1] to move to the snapshot cancel Snapshot exit screen

screen.
After 7 minutes 30 seconds elapsed, the
screen automatically switches to the snap-
shot exit screen.
Snapshot execution screen
5) Adjustment
When this screen (Adjustment Menu screen)
is displayed first, the menu of "Load Meter" is
highlighted.
Press [F1] to return the SERVICE MENU pressing [F3] highlights the uppermost menu.
SELECT screen. Press [F4] to highlight the upper menu.
Press [F6] to move to the snapshot trigger If the uppermost menu is highlighted,
confirmation screen. pressing [F4] highlights the lowermost menu.
Press [F1] to return the SERVICE MENU
Snapshot cancel screen SELECT screen.
Press [F6] to move to the execution screen
for the menu highlighted at present. (For
more information, refer to the description of
the screen.)
Adjustment Menu screen for menu selection
Press [F1] to move to the snapshot cancel

screen.
This screen remains displayed a few
seconds, and then switches to the SNAP-
SHOT TRIGGER screen.
WA1200-6 10-261
Electrical system
When this screen (Adjustment Menu (1) Adjustment Menu (2) AJSS screen
Load Meter screen) is displayed first, the
menu of "Boom Angle Sensor (Upper)" is
highlighted.
Press [F1] to return to the Adjustment Menu
screen for menu selection.
the screen.)
When this screen (Adjustment Menu (3)
Work Equipment screen) is displayed, the
Adjustment Menu (1) Load Meter screen
menu of "Boom Ang. Sensor (Upr) (Eqp. Ctrl)
Adj." is highlighted.
Press [F3] to highlight the lower menu. (Scroll
function)
(Scroll function)
Press [F1] to move back to the adjustment
menu selection screen.
When this screen (Adjustment Menu (2) the screen.)
AJSS screen) is displayed, the menu of
"AJSS Neutral Position Adjustment" is high- Adjustment Menu (3) Work Equipment
lighted. screen
Press [F1] to move back to the adjustment
the screen.)
10-262 WA1200-6
Electrical system
1] Adjustment (load meter)

Load Meter screen) is displayed first, the
menu of "Boom Ang. Sensor (Upr) (Eqp
Ctrl) Adj." is highlighted.
menu.
menu.
Press [F1] to return to the Adjustment
Menu screen for menu selection.
When this screen (Adjustment Menu (4) T/M
Press [F6] to move to the execution
screen), the menu of "T/M Trigger Learning
screen for the menu highlighted at
Data Reset" is highlighted.
present. (For more information, refer to
the description of the screen.)
Adjustment Menu (1) Load Meter screen
Press [F1] to return to the Adjustment Menu
the screen.)
Adjustment Menu (4) T/M screen

Menu (1) Load Meter screen.
Press [F6] to send the set signal to the
main monitor.
The message below appears according
to the command (setting completion or
wrong setting) from the main monitor.
When setting is completed: "Setting
Completed"
When setting is not completed: "Wrong
Setting"
Until receiving a command: "In setting"
WA1200-6 10-263
Electrical system
Boom Angle Sensor (Upper) Adjustment If the current set value cannot be received
screen from the main monitor for 10 seconds or
more, the screen switches to the abort
screen.
Press [F3] once to reduce the current set
value by 1 [t].
Note that the switch operation is not
accepted until the current set value is
sent from the main monitor (while "---" is
displayed).
Press [F4] once to increase the current
set value by 1 [t].
Note that the switch operation is not
accepted until the current set value is
displayed).
The numeric value must not exceed the
Press [F1] to return the Adjustment Menu
upper and lower limits of setting range.
(1) Load Meter screen.
q Numeric value setting range
Metric ton: 20 to 99 [t]
main monitor.
US ton: 22 to 99 [t]
Note that if the value of 99 [t] in metric or
US tons is set to the set load, no alarm is
wrong setting) from the main monitor.
raised irrespective of the payload.
q When the unit setting is switched be-
Completed"
tween metric ton and US ton, the re-
cord previous set value is reduced to
Setting"
that in the specified unit and is dis-
played on the screen.
(example)
Boom Angle Sensor (Lower) Adjustment
If you set the payload 20 [t] in metric ton
screen
and change the unit to US ton in other
screen, US ton 22 [t] is that is equal to
metric ton 20 [t] is displayed when you
return to the Payload Setting screen
again.
q Default
The default value is 99 [t], setting the
machine monitor system in no alarm
mode for the payload.
Press [F6] to accept the current set value
of payload and send it to the main
monitor.
When the main monitor receives the
change, the screen returns to the Adjust-
When this screen (Payload Setting ment Menu (1) Load Meter screen.
screen) is switched from the standard When the multi-function monitor cannot
screen, the current set value of payload is receive the reception notice from the
displayed. main monitor for 10 seconds or more after
The current set value is displayed informing the main monitor of the
according to the information from the accepted set value, the screen switches
main monitor. "---" is indicated for the set to the abort screen.
value until the value is sent from the main Note that the switch operation is not
monitor. accepted until the current set value is
displayed).
10-264 WA1200-6
Electrical system
Press [F1] to cancel the setting and return [*1]: The title displays the setting item.
to the Adjustment Menu (1) Load Meter
screen. 2] Adjustment (AJSS)
Payload Setting screen AJSS screen) is displayed, the menu of
"AJSS Neutral Position Adjustment" is
highlighted.
menu.
Press [F4]to highlight the upper menu.
menu.
As for the triangle marksE and E that
appear above and below the figure
respectively, when the figure is lower
Adjustment Menu (2) AJSS screen
limit of the range, onlyR appears.
When the figure is upper limit of the
range, only Rappears.

the multi monitor to switch to this screen
when aborted. After the transition, the
multi monitor (KOMTRAX Plus) performs
the processing.
move to the Adjustment Menu (1) Load
Meter screen.
When the communication error with the

more during the adjustment, the screen Press [F1] to return to the Adjustment
returns to Service Menu screen without Menu (2) AJSS screen.
going through the abort screen. Press [F6] to send the set signal to the
work equipment controller.
Abort confirmation screen of load meter The message below appears according
relevant setting to the command (setting completion or
wrong setting) from the work equipment
controller.
Completed"
Setting"
WA1200-6 10-265
Electrical system
AJSS Neutral Position Adjustment screen AJSS EPC Output Current Adjustment
screen

adjustment current value is displayed a As for the triangle marks E and R
according to the information from the that appear above and below the fig-
work equipment controller. ure respectively, when the figure is
"---" is indicated for the value until the lower limit of the range, only E ap-
information is sent from the work equip- pears. When the figure is upper limit of
ment controller first. the range, only R appears.
Press [F1] to move back to the Adjust-
ment Menu (2) AJSS screen. When this screen is displayed first, the
Press [F3] to send the DOWN signal to table pattern number is displayed
the work equipment controller. according to the information from the
After the transmission, the multi-function work equipment controller.
monitor updates the adjustment current "–" is displayed for the number until the
value according to the signal from the information is received first after the
work equipment controller. screen transition.
This screen only displays the changed Press [F1] to return to the Adjustment
numeric value according to the work Menu (2) AJSS screen.
equipment controller, so no button opera- Press [F6] to send the change signal of
tions of the multi-function monitor are the AJSS oil pressure command table
required for the numeric value change. pattern to the work equipment controller.
Press [F4] to send the UP signal to the After the transmission, the multi-function
work equipment controller. monitor updates the pattern number
After the transmission, the multi-function according to the signal from the work
monitor updates the adjustment current equipment controller.
value according to the signal from the This screen only displays the changed
work equipment controller. numeric value according to the work
This screen only displays the changed equipment controller, so no button opera-
numeric value according to the work tions of the multi-function monitor are
equipment controller, so no button opera- required for the numeric value change.
tions of the multi-function monitor are
required for the numeric value change.
10-266 WA1200-6
Electrical system
AJSS oil pressure command table pattern Press [F4] to highlight the upper menu.
change screen (Scroll function)
menu.
Adjustment Menu (3) Work Equipment

screen

the multi-function monitor move to this
screen when aborted. After the transition,
the multi monitor (KOMTRAX Plus)
performs the processing.
switch to the Adjustment Menu (2) AJSS
screen.
controller continues for 0.5 seconds or
more during the adjustment, the screen
returns to the Service Menu screen
Abort confirmation screen of AJSS rele-

vant setting

(3) Work Equipment screen.
3] Adjustment (work equipment) to the command (setting completion or
When this screen (Adjustment Menu (3) wrong setting) from the work equipment
Work Equipment screen) is displayed controller.
first, the menu of "Boom Ang. Sensor When setting is completed: "Setting
(Upr) (Eqp Ctr) Adj." is highlighted. Completed"
Press [F3] to highlight the lower menu. When setting is not completed: "Wrong
(Scroll function) Setting"
If the lowermost menu is highlighted, Until receiving a command: "In setting"
menu.
WA1200-6 10-267
Electrical system
Boom Ang. Sensor (Upr) (Eqp Ctr) Adj. Press [F1] to return to the Adjustment
screen Menu (3) Work Equipment screen.
controller.
Completed"
Setting"
[Special notes]
This screen provides two types of adjust-
ments and the work equipment controller
selects the adjustment based on the
Press [F1] to move back to the Adjust-
engine speed.
ment Menu (3) Work Equipment screen.
(The multi monitor is not involved in it.)
Adjustment item
q Adjusting lift arm lever LOWER detent
position
q Adjusting boom LOWER EPC current
controller.
Dead zone variation adjustment screen of
boom lower lever & EPC
Completed"
Setting"
[Special notes]
engine speed.
(The multi monitor is not involved in it.)
Adjustment item
q Adjusting lift arm lever RAISE detent
position
q Adjusting boom RAISE EPC current
Dead zone variation adjustment screen of Press [F1] to return to the Adjustment
boom raise lever & EPC Menu (3) Work Equipment screen.
controller.
Completed"
Setting"
[Special notes]
engine speed.
10-268 WA1200-6
Electrical system
(The multi monitor is not involved in it.) When this screen is displayed first, the
Adjustment item table pattern number is displayed
q Adjusting bucket TILT detent position according to the information from the
q Adjusting bucket TILT EPC current work equipment controller.
Dead zone variation adjustment screen of "–" is displayed for the number until the
bucket tilt lever & EPC information is received first after the
screen transition.
Menu (3) Work Equipment screen.
Press [F6] to send the change signal of
the boom lever pattern to the work equip-
ment controller.
After the transmission, the multi-function
monitor updates the pattern number
according to the signal from the work
equipment controller.
This screen only displays the changed
numeric value according to the work
equipment controller, so no button opera-
Menu (3) Work Equipment screen.
Boom Lever Pattern Change screen
controller.
Completed"
Setting"
[Special notes]
This screen provides single type of
adjustment.
Adjustment item
q Adjusting bucket DUMP EPC current
Dead zone variation adjustment screen of

bucket dump lever & EPC
WA1200-6 10-269
Electrical system
When this screen is displayed first, the Press [F4] to send the UP signal to the
table pattern number is displayed work equipment controller.
according to the information from the After the transmission, the multi-function
work equipment controller. monitor updates the numeric value (%)
"–" is displayed for the number until the according to the signal from the work
information is received first after the equipment controller.
screen transition. This screen only displays the changed
Press [F1] to return to the Adjustment numeric value according to the work
Menu (3) Work Equipment screen. equipment controller, so no button opera-
Press [F6] to send the change signal of tions of the multi-function monitor are
the bucket lever pattern to the work required for the numeric value change.
After the transmission, the multi-function Boom Lower Stop Modulation Adj. screen
monitor updates the pattern number
according to the signal from the work
Bucket Lever Pattern Change screen
a As for the triangle marks E and R

that appear above and below the fig-
ure respectively, when the figure is
lower limit of the range, only E ap-
pears. When the figure is upper limit of
the range, only R appears.

the multi-function monitor to move to this
When this screen is displayed first, the the multi-function monitor (KOMTRAX
table pattern number is displayed Plus) performs the processing.
according to the information from the After reading the message, press [F5] to
work equipment controller. move to the Adjustment Menu (3) Work
" -" is displayed for the value until the Equipment screen.
information is received first after the When the communication error with the
screen transition. controller continues for 0.5 second or
Press [F1] to return to the Adjustment more during the adjustment, the screen
Menu (3) Work Equipment screen. returns to Service Menu screen without
Press [F3] to send the DOWN signal to going through the abort screen.
the work equipment controller.
After the transmission, the multi-function
monitor updates the adjustment current
value according to the signal from the
10-270 WA1200-6
Electrical system
Abort confirmation screen of work equip- Adjustment Menu (4) T/M screen
ment relevant setting

[*]: The title displays the setting item. Menu (4) T/M screen.
Press [F5] to send the reset signal to the
4] Adjustment (transmission controller) transmission controller and move to the
When this screen (Adjustment Menu (4) setting completion screen.
T/M screen) is displayed first, the menu of Use the real time monitor function to
"T/M Trigger Learning Data Reset" is check whether the data is reset.
highlighted.
Press [F3] to highlight the lower menu. T/M Trigger Learning Data Reset screen
menu.
menu.

Menu (4) T/M screen.
wrong setting) from the transmission
controller.
Completed"
Setting"
WA1200-6 10-271
Electrical system
T/M Trigger Learning Data Reset screen 6) Option setting

(setting completion screen) When this screen (Option Setting screen) is
displayed first, the menu of "boom Specifica-
tion" is highlighted.
the settings currently selected are displayed
on the screen according to the information
from the main monitor. (The main monitor
records all option settings.)
Press [F3] to highlight the lower item.
If the lowermost item is highlighted, pressing
[F3] highlights the uppermost item.
Press [F4] to highlight the upper item.
If the uppermost item is highlighted, pressing
[F4] highlights the lowermost item.
Press [F1] to return to the Service Menu
Press [F6] to change the option setting of the
item highlighted at present. (If the setting is
the multi-function monitor to move to this
changed, the change is sent through the
network.)
the multi-function monitor (KOMTRAX
The main monitor also saves all option
Plus) performs the processing.
settings so that it can detect disagreement
between the option settings and actual
move to the Adjustment Menu (4) T/M
machine conditions.
screen.
Press [F2] to move to the next page of the
Option Setting screen.
more during the adjustment, the screen
Option Setting screen (1/2)
returns to the Service Menu screen
Abort confirmation screen of transmission

relevant setting
Option Setting screen (2/2)
10-272 WA1200-6
Electrical system
Default Maintenance remaining time screen (page 1)

Default Option
Boom specification STD Hi Lift Ext Hi Lift
Tire type STD OPT1 OPT2
± 12% (in incre-
Tire size correction 0%
ments of 2 %) (*1)
Economy operation
ADD NO ADD
indication lamp
3rd gear prophibition NO ADD ADD
Wall digging prophibi-
ADD NO ADD
tion
Tire slip prevention
ADD NO ADD
control
Dump truck approach
ADD NO ADD
control
Travel speed control TYPE 1 TYPE 2
AT the over load
NO ADD ADD
boom rise stop control * The maintenance monitor screen has four
Fixed to
Engine mode AUTO Fixed to E pages. For information on other pages,
P
To display the engine mode screen, you must enter the
refer to "2-4) Maintenance monitor" in the
special ID when entering the service ID. user menu.
(*1) The value changes in following order:
+0o+2o+4o…o+12o-2o-4o…o-12o+0 When this screen is displayed, numeral "1" is
displayed.
Press [F1] to revert the change interval back
7) Maintenance monitor (for service)
to the one before moving to this screen and
The remaining time to next maintenance is
return to the previous screen.
displayed on the maintenance monitor
Press [F2] delete a numeral entered last.
screen.
If no numeral is entered, the screen does not
Press [F1] to return to the Service Menu
change.
screen.
Press [F3] to highlight a numeral on the left of
Press [F5] to move to the next page.
the numeral selected (highlighted) at
If page 4 is displayed, pressing [F5] displays
present.
page 1.
If the numeral highlighted at present is "1",
Press [F2] to move to the previous page.
pressing [F3] highlights "0".
If page 1 is displayed, pressing [F2] displays
Press [F4] to highlight a numeral on the right
page 4.
of the numeral selected (highlighted) at
present.
pressing [F4] highlights "1"
Press [F5] to select the numeral highlighted
at present and display the numeral in the
entry field (input from the upper digit).
Press [F6] to move to the maintenance
Press [F6] to accept the current change
interval change screen for the menu item
interval displayed in the entry field and return
highlighted at present.
The original elapsed time is valid and the
remaining maintenance time is recomputed.
(Example)
If the maintenance interval time is changed
from 500 h to 400 h and 380 h has elapsed
before the change, the remaining mainte-
nance time is recomputed as follows; 400 h –
380 h = 20 h
As the remaining maintenance time is less
than 30 h in this case, the remaining time is
highlighted in yellow on the screen.
WA1200-6 10-273
Electrical system
Maintenance interval change screen Unit Setting screen
9) Deleting memory
8) Unit selection When this screen is displayed, numeral "1" is
Use this screen to select the unit system of displayed.
numeric values displayed on the multi-func- Press [F1] to return to the Service Menu
tion monitor screen. screen.
The unit set in this screen has an impact on Press [F2] delete a numeral entered last.
the travel speed unit in the main monitor and If no numeral is entered, the screen does not
the unit of the load meter. change.
When "ENGLISH" is selected as a unit Press [F3] to highlight a numeral on the left of
system, the travel speed unit in the main the numeral selected (highlighted) at
monitor changes to "MPH" and the display present.
unit of the load meter changes to "short ton". If the numeral highlighted at present is "1",
When other unit system is selected, the pressing [F3] highlights "0".
travel speed unit and the display unit of the Press [F4] to highlight a numeral on the right
load meter remain "km/h" and "metric ton" of the numeral selected (highlighted) at
respectively. present.
When this screen is displayed first, the pressing [F4] highlights "1"
current unit system is highlighted. Press [F5] to select the numeral highlighted
Press [F1] to return to the Service Menu at present and display "*" in the entry field
screen. (input from the upper digit).
Press [F3] to change the highlighted unit Press [F6] to accept the current ID displayed.
system in order of METRICoENG- When it is correct ID, the screen switches to
LISHoSIo METRIC. the MEMORY CLEAR screen.
Press [F4] to change the highlighted unit When it is a wrong ID, the screen remains
system in order of METRICoSIoENG- unchanged.
LISHo METRIC. However, the text changes to "Enter a correct
Press [F6] to accept the current unit system ID." and the wrong ID is deleted from the
highlighted and return to the Service Menu entry field.
screen. When a correct ID is entered, the screen
switches the MEMORY CLEAR screen.
Or, press [F1] to return to the Service Menu
screen.
10-274 WA1200-6
Electrical system
Service ID input screen MEMORY CLEAR confirmation screen
When this screen is displayed first, the menu

of "Failure History Data" is highlighted. a The item name selected appears in
Press [F1] to return to the Service Menu "*****".
screen. q Failure History data, Maintenance Da-
Press [F3] to highlight the lower item. ta, Trend Data, Load Map Data, Snap
If the lowermost item is highlighted, pressing Shot Data
[F3] highlights the uppermost item.
Press [F4] to highlight the upper item. 10)Serial/GCC number setting
If the uppermost item is highlighted, pressing This screen displays the current settings.
[F4] highlights the lowermost item. Press [F1] to return to the Service Menu
Press [F6] to move to the MEMORY CLEAR screen.
confirmation screen of the menu item high-
lighted at present. Serial/GCC No. Setting screen
MEMORY CLEAR screen
Press [F2] to return to the MEMORY CLEAR

screen without deleting the memory.
Press [F5] to delete the memory and return to
the MEMORY CLEAR screen.
WA1200-6 10-275
Electrical system
Multi-function monitor 10-276
10-276 WA1200-6
Electrical system
Work equipment and AJSS control system
Work equipment and AJSS control system 10-27

*AJSS: Advanced joystick steering system
Electrical circuit diagram of work equipment and AJSS control 10-27
WA1200-6 10-277
Electrical system
10-278 WA1200-6
Electrical system
Work equipment control 10-279

1. Work equipment lever operation
Function
q The work equipment controller detects the lever stroke of lift arm RAISE/LOWER and bucket
TILT/DUMP operations from the signals of the work equipment lever potentiometer, and then controls
each EPC valve installed on the main valve by using current to actuate the main spool, thereby oper-
ating the work equipment.
WA1200-6 10-279
Electrical system
q The work equipment lever is equipped with detent notches and both the lift arm and bucket are con-
trolled so that they reach their maximum speeds at a position short of each detent. When the lever
crosses over the LOWER detent, the lift arm enters "FLOAT" condition in which it can be moved by an
external force.
10-280 WA1200-6
Electrical system
2. Work equipment neutral lock

Function
q When the work equipment lock lever is set to the LOCK position, the work equipment lock switch be-
comes OPEN, and then the controller drives the work equipment neutral lock valve. When the valve is
actuated, the EPC pilot source pressure is shut off. As the result, the work equipment cannot move.
a The detent function does not work and the lever is not held in the detent position while the work equip-
ment is locked.
q When the work equipment lock lever is in LOCK position, moving the work equipment lever to a oper-
ation position and setting the lock lever to FREE position does not cancel the work equipment lock con-
dition. This safety function keeps work equipment lock condition until all the work equipment control
are returned to neutral.
Operation table
Operation of work equip- Operation of
Operation by man Input to controller Output from controller
ment machine
Work equipment lock Work equipment lock Work equipment lever Work equipment neu-
Oil pressure
lever lever switch potentiometer tral lock valve
Low position OFF ON
– Cut
(LOCK) (OPEN) (24 V)
Low oHigh position OFF Work equipment lever in ON
Cut
(unlocking) (OPEN) operating position (24 V)
Work equipment lock is
Low oHigh position OFF released and then all OFF
Operative
(unlocking) (OPEN) control are returned to neu- (OPEN)
tral
High position ON OFF
– Operative
(FREE) (CLOSE) (OPEN)
WA1200-6 10-281
Electrical system
Flowchart
10-282 WA1200-6
Electrical system
3. Play of lever at neutral position and work equipment speed

Function
q The work equipment lever has a play of 5% in lever stroke at the neutral position. The work equipment
starts to move when the lever crosses over the play position.
q The work equipment speed for the lever stroke can be changed by changing the setting of the control-
ler.
q To change the work equipment speed, five changeable tables are prepared for the lift arm, and three
tables for the bucket.
a For the adjustment procedure and the characteristics of each table, see Testing and adjusting,
"Change of lift arm tables and bucket tables".
WA1200-6 10-283
Electrical system
4. Trigger current control at startup

Function
q To prevent the work equipment from making delay in response to the operation of the work equipment
lever, the work equipment pump carries trigger current when the lever starts to move from the neutral
position (at startup), thereby improving the response of the work equipment.
1) When the lever starts to move from the
neutral position
2) Operation when the lever crosses the detent
10-284 WA1200-6
Electrical system
3) Operation when the lever is moved from 5) Operation when the lever is held at a certain
acceleration to deceleration control position
a Determination of acceleration and decel-
eration control
The previous (10 msec. before) current
output value and the new current output
value are compared.
[Acceleration]: Previous current output
value < New current output value
[Deceleration]: Previous current output
value > New current output value
[Hold]: Previous current output value =
New current output value
a Calculation of output current
When the lever is in acceleration control
q Output current value = Command cur-
rent value (current value determined
from the target flow rate) + Hysteresis
current value
When the lever is in deceleration control
q Output current value = Command cur-
rent value (current value determined
from the target flow rate)
When the lever is in hold control
q The previous output current value is
maintained.
4) Operation when the lever is moved from

deceleration to acceleration control
WA1200-6 10-285
Electrical system
6) During calibration of lever and EPC 1) Stop modulation for lift arm LOWER
a This control is not applied during the cali- Equivalent of the valve slow return function
bration. q The lift arm LOWER stop speed can be
changed by adjusting the deceleration
7) Trigger table flow rate for the stop modulation using the
Lift calibration function.
Lift Bucket Bucket
arm The modulation does not function if the
arm RAISE TILT DUMP
LOWER flow rate at the start of deceleration is
Trigger 30% or more of the target flow rate.
0.0 sec 0.0 sec 0.0 sec 0.0 sec
time a For the deceleration flow rate, see 3) Ta-
Trigger
800 mA 800 mA 800 mA 800 mA ble (set value).
current
Hyster- : The default of calibration set value is
esis 0 mA 0 mA 0 mA 0 mA 100 %.
time 2) Stop modulation for lift arm RAISE
Equivalent of the valve slow return function
q Permission flag of trigger output current.
q The lift arm RAISE stop speed can be
(Mask bit is used for the first increment of
changed by adjusting the deceleration
time.)
flow rate for the stop modulation using the
q Trigger output current is allowed to flow
calibration function.
when the controller recognizes that the le-
The modulation does not function if the
ver is in the neutral position for 1 second
flow rate at the start of deceleration is 30
or more.
% or more of the target flow rate.
a Trigger current is not produced while
a For the deceleration flow rate, see 3) Ta-
the lever is rapidly moved.
ble (set value).
: The default of calibration set value is
5. Lift arm stop modulation
100 %.
Function
q When the operator performs lift arm RAISE
3) Table (set value)
or LOWER stop operation more quickly than
Deceleration flow rate Flow rate
a certain speed, the work equipment control- Opera- at decel-
ler starts the modulating function to prevent tion 0% 100 % 200 % eration
lift arm stop shock. start
q The operation of this "stop modulation func- Less
tion" can be adjusted by changing the setting than 30
0.75 0.5 0.05
of the controller. RAISE
%/msec %/msec %/msec
% of tar-
a For the procedure and precautions of chang- get flow
ing the modulation setting, see Testing and rate
adjusting, "Change of stop modulation at lift Less
than 30
arm RAISE/LOWER". 1.05 0.7 0.15
LOWER % of tar-
%/msec %/msec %/msec
get flow
rate
a Note that the modulation does not func-
tion when the deceleration flow rate is 0
%.
10-286 WA1200-6
Electrical system
CASE A: Lever command flow rate > Modulation command flow rate
q The control current is output according to the lever command flow rate.
CASE B: Lever command flow rate < Modulation command flow rate
q The control current is output according to the modulation command flow rate.
CASE C: Deceleration and re-acceleration from the lever neutral position

a The larger command flow rate is adopted.
WA1200-6 10-287
Electrical system
CASE D: When the lever is operated in reverse direction (lift arm RAISE) for lift arm stop.
a Modulation output is stopped when the RAISE command exceeds 15%.
10-288 WA1200-6
Electrical system
Bucket positioner control 10-289

Functions
q The controller constantly detects operating direction of the lever from the bucket control lever potentiom-
eter and the bucket position (above or below level) from the bucket cylinder proximity switch.
q When the bucket control lever is set to “TILT detent” position and the bucket is tilted to the reaction position
of the bucket cylinder proximity switch, the bucket tilt detent is canceled.
q The bucket tilt EPC output always follows the input of the bucket tilt lever.
Operation of tilt detent solenoid
WA1200-6 10-289
Electrical system
Lift arm remote positioner 10-290
1. Function 2) Lower lift arm stop (with lower lamp ON)

q The lift arm remote positioner functions to q When the lift arm control lever is moved to
slow the lift arm to a halt in RAISE and LOW- the "float detent" position, the lift arm
ER operations. starts to slow at a position 9 deg. short of
a The controller keeps detecting the operat- the set position, and the float detent is re-
ing direction of the lift arm control lever leased at a position 2 deg. short of the set
from its potentiometer and the angle (po- position to provide lift arm stop modula-
sition) of the lift arm from its angle poten- tion control.
tiometer. q The lift arm starts to go down again if the
1) RAISE kick-out (with RAISE lamp ON) lift arm control lever is held at the position.
q When the lift arm control lever is moved to * The float detent only functions when
the "raise detent" position, the lift arm the remote positioner lower stop mode
starts to slow at a position 9 deg. short of is not selected.
the set position, and the raise detent is re- * The remote positoner does not func-
leased at a position 2 deg. short of the set tion if the lever is in the detent position
position to provide lift arm stop modula- with the lift arm angle below the hori-
tion control. zontal position, and the float detent
q The lift arm is raised by the operator ex- function (no automatic halt) only is
cept when it is in the "raise detent" posi- activated.
tion.
* The raise detent only functions when
the remote positioner raise stop mode
is not selected.
* The remote positoner does not func-
tion if the lever is in the detent position,
and the kick-out function only (stop-
ping the lift arm at TOP) is activated.
10-290 WA1200-6
Electrical system
2. Selection of remote positioner mode and setting of stop angle

1) Selecting remote positioner mode
(Selection by the raise set switch (CN-L06(13)) and lower set switch (CN-L06(3)))
1] Selection of remote positioner raise stop mode
q The controller determines whether the raise stop function is selected from the raise set switch
input.
q The selection status is indicated by the raise stop lamp and the buzzer.
2] Selecting remote positioner lower stop mode

q The controller determines whether the lower stop function is selected from the lower set switch
input.
q The selection status is indicated by the lower stop lamp and the buzzer.
Selection mode Stop position

Selec Raise Lower (*1) Lower (*2)
Raise/Lower
tion Raise stop Lower stop Min. 0 deg. 0–-37 deg. 0–-33 deg.
stop
Raise 0 deg.: Lift arm horizontal position (Default
selec- ON(q) OFF(Q) ON(q)
for both raise and lower)
tion
Lowe
(*1): STD lift arm
r (*2): Hi Lift lift arm
OFF(Q) ON(q) ON(q) a The calibration of the raise position is per-
selec-
tion formed by the multi-function monitor.
[Switch built-in indicator output]
Lamp lights up (Enabled = ON: q)
Lamp goes out (Disabled = OFF: Q)
a Available setting range of remote posi-
tioner stop position
(Available setting range of raise/lower
stop position)
WA1200-6 10-291
Electrical system
2) Input/output
10-292 WA1200-6
Electrical system
3) Control details
1] Raise position setting
Remote positioner raise
1 See 1. 1).
stop control
Availabil-
ity condi- Work equipment lever (lift arm) stroke: Neutral (within ±5%)
tions
(1) Raise the lift arm to the desired position.
(2) Press the remote positioner raise set switch (for less than 1 second).
(3) When the position at the time of the switch depression falls within the setting
range, the angle at the time of the switch depression is saved, the set completion
buzzer beeps twice (transmitted to the monitor), and the switch built-in indicator
Setting lights up.
method (4) If the position is out of the range (the lift arm angle is less than 0 deg.) and a sen-
sor error occurs, setting is not accepted.
Setting of
(The buzzer does not sound and the set position is unchanged.)
remote posi-
(5) Operation of the set switch for less than 1 second always changes the set posi-
2 tioner raise
tion.
stop angle
(The set status and position are maintained after the key is turned off.)
point
(1) Press the remote positioner raise set switch for 1 second or more.
(2) When the position falls within the setting range at the time of the switch depres-
sion, the position is temporarily set.
(3) The position is temporarily set at (2), but after a lapse of 1 second with the switch
pressed, the set cancellation buzzer sounds(transmitted to the monitor), the raise
Resetting
stop mode is canceled and the switch built-in indicator goes out. *Resetting can
method
be made at all lift arm angles.
(4) Remote positioner raise stop control is not performed. Lift arm kick-out control
only is conducted.
(The set status is maintained after the key is turned off.)
(The position reset (0 deg. setting) function is eliminated.)
2] Lower position setting

Remote positioner lower
1 See 1. 2).
stop control
Availabil-
ity condi- Work equipment (lift arm) lever stroke: Neutral (within ±5%)
tions
(1) Lower the lift arm to the desired position.
(2) Press the remote positioner lower set switch (for less than 1 second).
(3) When the position at the time of the switch depression falls within the setting
range, the angle at the time of the switch depression is saved, the set completion
buzzer beeps twice (transmitted to the monitor), and the switch built-in indicator
Setting lights up.
method (4) If the position is out of the range (the lift arm angle is other than ** to 0 deg.) and a
sensor error occurs, setting is not accepted. (The buzzer does not sound and the
Setting of
set position is unchanged.)
remote posi-
(5) Operation of the set switch for less than 1 second always changes the set posi-
2 tioner lower
tion.
stop angle
(The set status and position are maintained after the key is turned off.)
point
(1) Press the remote positioner lower set switch for 1 second or more.
(2) When the position falls within the setting range at the time of the switch depres-
sion, the position is temporarily set.
(3) The position is temporarily set at (2), but after a lapse of 1 second with the switch
pressed, the set cancellation buzzer sounds(transmitted to the monitor), the lower
Resetting
stop mode is canceled and the switch built-in indicator goes out. *Resetting can
method
be made at all lift arm angles.
(4) Remote positioner lower stop control is not performed. Float detent control only is
performed.
(The set status is maintained after the key is turned off.)
(The position reset (0 deg. function) function is eliminated.)
a For the description marked with ** in the setting method (4), see the table in "Available setting range
of remote positioner stop position".
WA1200-6 10-293
Electrical system
3. Output conditions of buzzer (main monitor) and switch built-in indicator

a The same output conditions are applied to
both raise and lower stop mode.
Selection switch
Output conditions Buzzer sound output Stop position
built-in indicator
The lift arm angle is within the setting range The set completion Controlled by the saved
when the remote positioner is not selected ON buzzer sounds when the value at the time of the
and the position set switch is set to ON. set switch is pressed. switch depression
The lift arm angle is out of the setting range Not controlled.
when the remote positioner is not selected Off None in particular Raise/Float detent is
and the position set switch is set to ON. controlled.
Controlled by the previ-
The lift arm angle is out of the setting range
ously saved value.
when the remote positioner is selected and ON None in particular
The saved value is
the position set switch is reset to ON.
unchanged.
Not controlled.
The saved value is
In case of sensor abnormality Off No (Error buzzer sounds) unchanged.
Raise/Float detent is
controlled.
Not controlled.
No (Error is displayed on
In case of set switch abnormality Off Raise/Float detent is
the multi monitor.)
controlled.
The lift arm angle is within the setting range The set completion Controlled by the saved
when the remote positioner is selected and ON buzzer sounds when the value at the time of the
the position set switch is reset to ON. set switch is pressed. switch depression
When the remote positioner function is not The indicator turns The indicator turns off
Not controlled.
selected off after a lapse of 1 after a lapse of 1 second
Raise/Float detent is
(When resetting is made with the switch second with the set with the set switch
controlled.
pressed for 1 second or more) switch pressed. pressed.
4. Saving remote positioner raise/lower set angle and raise/lower stop modes in EEPROM
q The battery disconnect switch allows EEPROM saving not just when the key is turned off but every
time setting is made.
10-294 WA1200-6
Electrical system
5. Lift arm detent control

1) ON/OFF conditions of lift arm raise detent 2) ON/OFF conditions of lift arm float detent
solenoid solenoid
1] In the raise stop mode 1] In the lower stop mode
Lift arm detent Raise solenoid Lift arm detent Float solenoid
Lever stroke (st) Lever stroke (st)
angle output angle output
Area A in the fig- Area C in the fig-
st > 60 ON st < -60 ON
ure ure
Area B in the fig- Area D in the fig-
– –
ure OFF ure OFF
st < 60 – -60 > st –
2] When the lower stop mode or remote 2] When the raise stop mode or remote
positioner is not selected positioner is not selected
a See "3) Lift arm kick-out function". a See "4) Lift arm float function".
WA1200-6 10-295
Electrical system
3) Lift arm kick-out function a When the kick-out function is activated,

ON/OFF conditions of lift arm raise detent the target stop angle is regarded as "-**
solenoid deg. in the table" to the maximum lift arm
Lift arm detent Raise solenoid angle of each lift arm specification.
Lever stroke (st)
angle output STD -5.0 deg
Area A in the fig- Hi Lift -5.0 deg
st > 60 ON
ure Extra Hi Lift -5.0 deg
Area B in the fig-
–
ure OFF
st < 60 –
4) Lift arm float function 5) Detent actuation with engine stopped

ON/OFF conditions of lift arm float detent q Detent solenoid remains OFF when the
solenoid engine is stopped.
Lever stroke (st) Float solenoid output q The engine shutdown is determined as
Above NEUTRAL
ON
follows.
-60<st
LOWER
OFF
St<-60
(*) : When the engine is running, the detent

solenoid is controlled according to 1),
2), and 6).
6) Safety assurance at the time of detent

cancellation
Lift arm kick-out function and remote posi-
tioner raise stop function
q The detent solenoid on the reverse side
(the lower detent solenoid for the cancel-
lation of the raise detent function) is set to
OFF for 1 second after the detent function
is canceled by the lower stop function.
10-296 WA1200-6
Electrical system
6. Lift arm raise stop modulation control

1) Command flow rate for deceleration of lift arm raise
Toward raise side from Stop angle Toward lower side from stop angle
stop angle
Target flow rate (%) 100 100 40 45 50 100 100
Lift arm angle (°) 15 10 0 -2 -4 -9 -15
1] Outline of deceleration to stop

a) Deceleration is controlled according to the deceleration curve A: when the lift arm is 9 deg. short of the
raise stop angle and 9 deg. short of the lift arm top angle (when the kick-out function works).
O
b) The raise detent is canceled when the lift arm is 2 deg. short of the raise stop angle.
O
(a) If the detent is canceled
The lift arm starts to decelerate and stop according to the deceleration modulation B from the modula-
tion start angle.
(b) If the operator hold the lever in the detent position
The lift arm is raised again according to the deceleration curve A and the oil flow reaches full when the
lift arm is 10 deg. above the stop angle.
Deceleration flow rate of raise stop modulation
Deceleration flow 0.2%/msec
rate
WA1200-6 10-297
Electrical system
Start angle of raise stop modulation (deg.)

q Pump flow rate (cc/sec.) = Pump flow rate (cc/rev.) x Engine speed (n/sec.) x Gear ratio (1.088)
Pump flow rate (cc/sec.) 30108 15054 7527 3764
TOP(32.8 deg.–49.47 deg.
1.5 1.0 0.4 0.2
)
25 deg.(16.4 deg.–32.8 de
Lift arm stop angle 1.0 1.0 0.4 0.2
g.)
Horizontal
1.0 1.0 0.4 0.2
(0 deg.-16.4 deg.)
I
Set position (set angle)
7. Lift arm lower stop control

Conditions Control details
Modulation at the
Start position of When detent is Lift arm Lift arm deceler-
Case time of detent
lift arm lowering canceled position ation control
cancellation
Automatic can-
A Below a level in x(*1)
cellation (Outside the limitation x
angle
B Manual holding range of deceleration) x(*1)
Automatic can- [Bucket placed hori-
C Q
cellation zontally on the ground] Q
D Above a level in Manual holding x
angle Below the limitation Above the decel-
E Manual holding angle of eration limitation x(*2)
deceleration angle
(*1): When the start position of lift arm lowering is below the horizontal position, no stop control is applied.
(*2): When the lift arm is below the deceleration
limitation angle, no stop control is applied.
10-298 WA1200-6
Electrical system
a The set angle of the limitation range of lift arm lower stop deceleration depends on the lift arm specifi-
cations.
STD -37 deg
Hi Lift -33 deg
Extra Hi Lift
WA1200-6 10-299
Electrical system
8. Lift arm lower stop modulation control

1) Deceleration control and deceleration modulation in Cases C and D in section 7 is applied.
a Modulation and deceleration control are not provided in Cases A and B.
Command flow rate for lift arm lower deceleration
Toward lower side Stop Toward raise side from stop angle
from stop angle angle
Target flow rate (%) 100 100 35 35 40 50 100 100
Lift arm angle (°) -15 -10 0 2 3 4 7 10
10-300 WA1200-6
Electrical system

a) Deceleration is controlled according to the deceleration curve A when the lift arm is 9 deg. short of the
lower stop angle.
O
b) When the lift arm is 2 deg. short of the lower stop angle
O
(a) If the detent is canceled (Case C)
The lift arm decelerates and stops according to deceleration modulation B.
(b) If the operator holds the lever in the detent position (Case D)
The lift arm starts to lower again according to the deceleration curve A and the flow rate reaches full
when the lift arm is 10 deg. above the stop angle.
Deceleration flow rate of lower stop modu-

lation
Deceleration flow Deceleration flow rate
rate at or over 40% at or below 40%
0.7%/msec 0.16%/msec
2) Deceleration control and deceleration modulation in Case E in section 7

a When the float detent holding and lift arm lower stop angles are -27 deg. and the deceleration lim-
itation angle is at or below +10 deg. (in case of an STD lift arm)
Command flow rate for lift arm lower deceleration (stop angle +9 deg. and -10 deg.)
Toward lower side Stop Toward raise side from stop angle
from stop angle angle
Target flow rate (%) 100 100 35 35 40 50 100 100
Lift arm angle (°) -15 -10 0 2 3 4 7 10

a) Deceleration is controlled according to the deceleration curve A when the lift arm is 9 deg. short of the
lower stop angle.
O
b) If the operator holds the lever in the detent position when the lift arm is 2 deg. short of the lower stop
angle,
The lift arm starts to lower again according to the deceleration curve A but stops decelerating and comes
to the float position at the deceleration limitation angle. (The target flow rate reaches 100%.)
WA1200-6 10-301
Electrical system
Control of semi auto-digging 10-302

1. Function q This function allows even inexperienced op-
q Semi auto-digging control allows the opera- erators to perform more efficient operation.
tor to perform automate bucket operation Two material modes, "Loose/Soft mode" and
while raising the lift arm. In this mode, the lift "Rock/Hard mode", are available in this
arm operating stroke, engine speed, and lift semi-auto digging. Select an appropriate
arm angle are detected and used to control mode to perform automatic bucket operation
the bucket EPC. that matches the characteristics of the mate-
rial.
Mode selection
No Object Mode
1 Gravel/sand Loose/Soft mode
2 Quarry/blasted rock Rock/Hard mode
2. System configuration
10-302 WA1200-6
Electrical system
3. Control method
q Highly responsive open-loop control for bucket operation without using feedback
q Operator intervention is allowed.
NC control 10-303 PNC control 10-303
Function Function
q NC control serves to set the swash plate angle of q PNC control serves to set the swash plate angle
the work equipment pumps to the minimum of the switch pump when the work equipment is
when no work equipment is operated so that fuel in operation so that sufficient oil flow is provided
consumption is reduced. to the work equipment.
1. ON/OFF conditions of NC control 1. ON/OFF conditions of PNC control
q When operation command is generated for q When operation command is generated for
the bucket or lift arm: OFF the bucket or lift arm with (hysteresis ON):
q Cases other than above: ON ON
2. Processes when NC control is set to ON/OFF q Cases other than above: OFF
ON : NC solenoid is energized (the swash Hysteresis
plates of the work equipment pump 1 q Default: Hysteresis = ON
and 2 are at minimum angle). q The hysteresis is set to OFF if work equip-
OFF : NC solenoid is de-energized (the ment pump pressure becomes > 29.4 MPa
swash plates of the work equipment {300 kg/cm2} with hysteresis ON
pump 1 and 2 are at maximum). q Hysteresis is set to ON if work equipment
pump pressure becomes Z 25.5 MPa
{260 kg/cm2} with hysteresis OFF
2. Processes when PNC control is set to ON/OFF
ON : PNC solenoid relay is actuated (SIG.
OUT0: ON).
: PNC solenoid is energized when relay is
actuated.
: Switch pump swash plate is maximized.
OFF: PNC solenoid relay is not actuated (SIG.
OUT0: OFF).
: PNC solenoid is de-energized when
relay is not actuated.
: Switch pump swash plate is controlled by
CLSS in conjunction with steering pump.
WA1200-6 10-303
Electrical system
AJSS control 10-304
Function
AJSS is a steering control system using a joystick. AJSS senses the frame articulation angle and dives the
pilot pressure system with feedback mechanism so that the machine turns in accordance with the tilting angle
of AJSS lever.
1. AJSS system
q In AJSS, both the joystick steering lever and the frame are connected to the rotary valve through the
linkage. If a disagreement occurs between the operating angle of the lever and the machine frame ar-
ticulation angle, the rotary valve supplies pilot pressure to the steering control valve to turn the machine
in the steering direction. When the operating angle of the lever and the machine frame articulation an-
gle coincide with each other. AJSS closes the rotary valve.
q AJSS allows steering operation even when there is a problem with the EPC valve because of the op-
eration of the pressure compensation valve.
q Even if the engine is stopped, AJSS allows steering operation by activating the diverter valve while the
transmission is rotating (traveling) with engine stopped.
10-304 WA1200-6
Electrical system
WA1200-6 10-305
Electrical system
2. AJSS neutral interlock

q When the engine is stopped and the joystick steering lever is placed at a position other than neutral
(disagreement between the operating angle of the lever and the machine frame angle), if the engine is
started again, the machine may start to turn immediately after the engine starts. In such case, the AJSS
prevents the engine start by driving the neutral safety relay to cut the engine start signal.
q If the steering lock lever is set to LOCK position while the joystick steering lever is in a position other
than neutral and the engine is running, there is a possibility that the machine articulates immediately
when the steering lock lever is set to FREE position, so the caution buzzer sounds in order to give the
operator a warning.
q Since the machine does not turn with the steering locked, operation of FR is prohibited by the trans-
mission controller. Therefore, if the forward-reverse switch of the joystick steering knob is set to a po-
sition other than neutral while the steering is locked, because there is a possibility that forward-reverse
operation occurs immediately after unlocked, the caution buzzer is sounded in order to call attention of
the operator.
10-306 WA1200-6
Electrical system
3. Speed-sensing steering
q In AJSS, the steering characteristics is changed in accordance with travel speed, by controlling the pilot
source pressure of the rotary valve with EPC.
q V-shape loading efficiency gains a higher priority at travel speed of 7 km/h or less, and the machine is
controlled to turn faster when the lever operating stroke is long.
q When travel speed is higher, the turning speed is reduced from the neutral range of lever operating
stroke, limiting sudden turning in rapid lever operation.
q These steering characteristics can change the turning speed for lever operating stroke by changing the
controller settings.
q It has three changeable tables.
a For the adjustment procedure and the characteristics of each table, see "Testing and adjusting: change
of AJSS hydraulic command table patterns".
AJSS characteristics
4. Adjustment of AJSS neutral position

q AJSS recognizes opening of the rotary valve made by lever operation with the frame angle sensor.
q To eliminate installation error of the sensors, AJSS requires the adjustment of neutral position for
straight machine frame and the rotary valve neutral.
a For the adjustment procedure, see Testing and adjusting, "Adjustment of AJSS neutral position".
WA1200-6 10-307
Electrical system
5. AJSS turn signal control

q In AJSS, since the turn signal can not be reset automatically, the turn signal automatic reset operation
is performed using the frame angle input in the controller.
1) Machine circuit
2) Operating and stopping turn signal

The operation and stop conditions of the right turn signal lamp are shown below (same for the left turn
signal).
Operation: When the right turn signal switch is pressed with the right turn signal lamp stopped, the turn
signal lamp flashes. Flashing is performed by the flasher unit.
Stop: When the following operation is performed with the right turn signal lamp in operation, the right
turn signal lamp stops.
Press the right turn signal switch again.
Press the left turn signal switch. In this case, the left turn signal lamp also starts to flash.
When the machine is faced directly to the front (less than 8 deg.) after the turn signal lamps start
to light up and the machine turns right 10 deg. or more, the right turn signal lamp stops. (Auto-
matic stop)
When the machine turns left 10 deg. or more after the turn signal lamps start to light up, the right
turn signal lamp stops. (Automatic stop)
10-308 WA1200-6
Electrical system
Real-time monitor 10-309

q The controller keeps checking whether following electronic devices are working normally; potentiometers
from which controller receives input signals, solenoid valves to which controller outputs signals.
q If a failure occurs in any one of these devices, the controller detects it and informs the operator of it by
displaying "Failure code" on the machine monitor.
q The status of the controller input/output signals can be checked by using the real-time monitor function of
the multi monitor.
q For the displayed items, see "Multi monitor", "3. Service menu, 1) Real-time monitor".
Work equipment and AJSS controller 10-309
WA1200-6 10-309
Electrical system
Input/output signal
[CN-L05][DEUTSCH-24P]
Input Input
and out- and out-
Pin No. Signal name Pin No. Signal name
put put
signals signals
1 Bucket lever potentio B Input 13 Boom lever potentio B Input
2 Looder pump press. sensor Input 14 Boom bottom press sensor Input
3 AJSS frame potentio Input 15 NC Input
4 GND_SIG_D 16 NC Output
5 NC Input 17 Semiauto looding loose mode SW. Input
6 NC Input 18 NC Input
7 Bucket lever potentio A Input 19 Boom lever potentio A Input
8 Boom angle sensor Input 20 NC Input
9 AJSS lever poteinto Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 NC Input 23 Semiauto looding rock mode SW. Input
[CN-L06]DEUTSCH-40P(1)
Input Input
and out- and out-
put put
signals signals
Input/out
1 NC Output 21 NC
put
Input/out
2 Winker SW. right Input 22 COMM_CAN_L_O
put
Input/out
3 Remots positioner levering set SW. Input 23 NC
put
4 NC Input 24 PWR_CTR_EXT Input
5 NC Input 25 Starter switch(IGN-C) Input
6 Active power up solenoid signal Input 26 Pnc solenoid 1 signal Input
8 Winker relay left Output 28 NC Input
9 Loader pump solenoid relay Output 29 NC
11 NC Output 31 NC
Input/out
12 NC 32 COMM_CAN_H_O
put
Input/out
13 Remote positioner lifting set SW. Input 33 NC
put
14 NC Output 34 NC
15 NC Input 35 lever pronibiting equipment SW. Input
16 Pnc solenoid 2 signal Input 36 NC Input
18 Winker relay right Output 38 Winker SW. left Input
19 Sw pump PNC soienoid relay Output 39 NC
10-310 WA1200-6
Electrical system
[CN-L07]DEUTSCH-40P(2)
Input Input
and out- and out-
put put
signals signals
1 PWR_IN_BATT Input 21 GND_PWR
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 Safety relay Output 24 PWR_CTR_KEY Input
5 Bucket tilting EPC Output 25 Bucket tilting EPC 2 Output
6 Boom lifting EPC Output 26 AJSS EPC Output
7 Work neutral lock solenoid Output 27 Magnetic detent of boom lever float Output
8 Remote positioner lifting lndicator Output 28 Boom lifting EPC 1 Output
NC (Tilt limiter ON/OFF (If
9 NC Input 29 Input
equipped))
10 Bucket cylinder tilt end SW. Input 30 NC Input
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 NC Output
15 Bucket dumping EPC Output 35 Bucket dumping EPC 2 Output
16 Boom lowering EPC Output 36 NC SOL Output
17 Magnetic detent of boom lever lift Output 37 Magnetic detent of bucket lever tilt Output
Remote positioner lovering indica-
18 Output 38 Boom lowering EPC 1 Output
tor
Loader pump swash plate cotrol
19 NC Input 39 Input
cacsel SW.
20 Bucket cylinder horizon SW. Input 40 NC Input
WA1200-6 10-311
Electrical system
Work equipment control lever
Work equipment control lever 10-312
10-312 WA1200-6
Electrical system
1. Lever 11. Seat

2. Rod 12. Ball
3. Centering spring 13. Detent spring
4. Metering spring 14. Rod
5. Nut 15. Body
6. Rod 16. Solenoid
7. Detent spring 17. Bushing
8. Retainer 18. Body
9. Lever 19. Retainer
10. Potentiometer 20. Rod
WA1200-6 10-313
Electrical system
Function 10-314
q When lever (1) is operated, rod (20) moves up
and down according to the lever operation
amount and potentiometer (10) rotates.
q The potentiometer detects the angle (stroke) of
the operation lever to output it as a signal voltage
to the controller.
q Single potentiometer is installed in the work
equipment and two relative signal voltages
shown in "output voltage characteristic" are out-
put.
Operation 10-314
When operation lever is operated 10-314
q Rod (20) is pushed upward by using spring (4)
according to the operation amount of lever (1).
q Lever (9) installed on the rotary shaft in potenti-
ometer (10) is coupled with rod (14).
q Potentiometer (10) outputs the signal voltage ac-
cording to the vertical stroke amount of rod.
When operation lever "Lift arm Lower" is operat-

ed 10-314
(The same holds for the operation of "Lift arm
Raise" and "bucket tilt")
q When lever (1) is pushed to move lift-arm-lower
rod (2) downward, ball (12) comes into contact
with protruding portion (a) of rod (14) along the
way of stroke. (before an electric detent starts to
work) When operation lever "Lift arm Lower" is re-
q When rods (2), (14) are pushed further, ball (12) leased 10-314
pushes upward retainer (8) supported by detent q To release "Lift arm Lower" position of lever (1),
spring (7) and goes outside to travel over pro- push down rod (20) with the force over the suc-
truding portion (a) of rod (14). tion force of solenoid suction. Or, when the sole-
q Opposite rod (20) is pushed upward by spring noid power is turned off, "Lift arm Lower" position
(4). is released and lever (1) returns to neutral posi-
q When rod (20) is pushed upward while solenoid tion.
(16) is live with electricity, nut (5) is sucked on
bushing (17).
q As rod (20) is kept in pushed up condition, even
if you release your hand from the lever, the "Lift
arm Lower" condition is kept.
10-314 WA1200-6
Electrical system
Transmission control system
Transmission control system 10-315

System overview 10-315
Auto shift
Modulation control
Kickdown function
Safety function
Manual shift
Modulation control
Kickdown function
Safety function
Traveling control function (forward/reverse, shifting range)
Self-diagnosis function
Status display (output, failure code)

Failure diagnosis (system error, disconnection to system,
detection of short-circuit)
Communication function
q The transmission control system consists of the transmission controller, FNR switch, shift-up/down switch,
engine speed sensor, modulation clutch output speed sensor, transmission oil temperature sensor and
ECMV (transmission clutch modulation valve) for all gears.
q The transmission controller controls shifts from the operator's signal and travel speed to the optimum
speed range. To reduce shifting shock (clutch engagement), modulation control of ECMV is applied for all
speed ranges.
q This system has various the safety functions. Sudden moving off prevention and transmission protection
(priority shift control) against directional change and downshift operation while traveling at a high speed.
These functions protect the transmission and clutches and improves their durability.
q The self-diagnosis function always monitors the input/output signal status to self-diagnoze the system. If
an error is detected with the self-dianosis function, the error information is sent to the multi monitor through
the network. If an error occurs, it can be checked with the multi monitor/KOMTRAX Plus.
q The transmission controller has communication function, and sends the gear shift information ("F", "N",
"R", "1"to "3") during traveling to the machine monitor. The machine monitor displays it.
WA1200-6 10-315
Electrical system
Electrical circuit diagram of transmission controller 10-316
10-316 WA1200-6
Electrical system
WA1200-6 10-317
Electrical system
10-318 WA1200-6
Electrical system
WA1200-6 10-319
Electrical system
Function 10-320
1. Auto shift function 4) Directional selector switch "R" position
Shift-up and shift-down of the transmission are In the same way in position F, the transmis-
controlled by the signals from travel direction, sion is shifted automatically between the 2nd
gear range, and the travel speed sensor, and 3rd (when the gear shift range is 3),
according to “Contents of control by transmis- according to the travel speed.
sion controller 1. Normal automatic shifting and 5) Skip shift
gear-shifting prohibition time table” which is If the accelerator pedal is depressed while
stored in the transmission controller memory. the machine is coasting in 3rd gear at speed
1) Shifting range (1st to 3rd) below 8.3 km/h, the transmission is shifted to
The maximum gear speed (gear shifting 2nd gear immediately so that the machine
range) in the automatic gear shift mode is can be accelerated easily.
limited. 6) Disapproved shift time
Example: Gear shift lever at 3: Between 2nd To prevent shift hunting after shifting, the
and 3rd speed time to maintain the gear speed is provided.
Gear shift lever at 2: 2nd speed only The non-shifting time varies depending on
Gear shift lever at 1: 1st speed only the shifting pattern. Refer to the "Transmis-
2) Directional selector switch "N" position sion controller details 1. List of normal auto-
At the neutral position, only the speed clutch matic shifting and non-shifting time".
of the transmission is operated.
3) Directional selector switch "F" position 2. Modulation control
When the directional selector switch is set To reduce shock in gear shifting (clutch engage-
from N to F, the ECMV of F clutch on the ment shock), the controller controls ON/OFF of
transmission is energized. When the shift all clutches according to the data memorized in
lever is positioned at 2 or 3, the machine the transmission controller so that optimum
starts at the 2nd speed. clutch pressure (including buid-up characteris-
a) Upshifting tics) is obtained depending on the hydraulic
(when the gear shift lever is at 3) circuit conditions such as the engine speed,
When the accelerator pedal is depressed transmission oil temperature and shifting
to increase the travel speed to approxi- pattern.
mately 9.7 km/h, the 3rd gear of ECMV is To reduce torque interruption, this modulation
turned ON and the 2nd gear is turned control is applied to the ECMV of the clutch that
OFF. (Gear is shifted to F3) is disengaged.
b) Downshifting
(when the gear shift lever is at 3)
When the accelerator pedal is released
during driving at the 3rd speed and the
travel speed is about 9.1 km/h, the ECMV
of the 2nd clutch is "energized" and that of
the 3rd clutch "de-energized". (Shifting to
F2) When the modulation clutch output
speed is less than 1,450 rpm, the 3rd
speed is maintained. (Coasting)
If travel speed decreases below approxi-
mately 1 km/h, the transmission is shifted
to the 2nd gear.
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Electrical system
3. Kickdown function 5) Manual shift

This function allows the operator to shift the gear If the travel speed data cannot be detected
speed to F1 forcibly by simply pressing the due to error of the travel speed sensor, the
kick-down switch if conditions for kick-down machine enters manual (shift) mode.
(traveling mode, gear speed and travel speed)
are satisfied. 6. Self-diagnosis function
1) Auto shift mode The transmission controller always monitors the
When the travel speed is less than 13 km/h input/output signals of the travel control system
during traveling forward or in reverse, kick- and performs self-diganosis. With the real time
down function is effective. It is also effective monitoring function of the multi monitor, the
while the machine is in the gear speed hold status of the controller input/output signal can be
mode (auto shift OFF mode). checked.
The kick-down is canceled and gear speed a For the displayed items, see "Multi monitor",
shift to 2nd when the travel speed is "3. Service menu, 1) Real-time monitor".
increased or travel direction is switched
between forward/reverse. 7. Communication function
2) Manual shift mode The transmission has a communication function
Kickdown is effective during traveling forward with CAN and receives tire correction data etc.
at the 2nd gear speed. from the multi monitor.
The kick-down is canceled and gear speed If a signal error occurs in the transmission
shift to 2nd when the upshift/downshift switch control system, the controller generates the
is pressed or travel direction is switched action code that depends on the seriousness of
between forward/reverse. the failure and sends it to the multi monitor. The
multi monitor displays it on the screen to warn
4. Traveling mode the operator for safe operation.
The traveling mode switch can change the mode The failure code generated are recorded in the
between auto and manual shift. In manual mode, multi monitor, they can be checked by using with
shifting is performed with the upshift/downshift the failure history menu of the multi monitor.
switch.
8. Transmission controller power supply
5. Safety function When the starting switch is turned to ON position
1) Transmission neutralizer function and the supply voltage is 20 V or more, and
When the steering lock lever is ON (locked) when power supply input of the transmission
or the machine is in stop before start of the controller solenoids is the 18 V or more, the
engine, this sets the transmission to the controller can drive the solenoids.
neutral position. This function sets the trans- If the power supply voltage decreases to 18 V or
mission in neutral when the steering lock below, all outputs are turned OFF and no control
lever is set to LOCL (locked) or the machine is made.
is in stop before start of the engine. The recovery condition is that the supply voltage
2) Neutral safety is 20 V or more. The neutral safety function is
When the directional selector switch is not at activated to enable traveling.
the N position at start-up, the transmission
controller maintains the neutral status and
does not allow start. (Prevention of sudden
start) When N signal is input after start-up, it
can be cancelled.
3) Priority of downshift switch
With the downshift switch, immediate down-
shifting can be performed allowing engine
braking during traveling downhill.
4) Transmission protection function
If the transmission is downshifted or the
travel direction is changed while the machine
is traveling at high speed in the 2nd or 3rd
gear speed, the gear speed and alarm
buzzer are controlled by this function to
protect the transmission.
WA1200-6 10-321
Electrical system
Transmission controller details 10-32

1. List of normal automatic shifting and non-shifting time
1) Normal automatic shifting (common for forward and reverse movement)
Gear shifting point
Engine speed conversion Travel speed conversion
Gear
Applicable conditions Output shaft speed [rpm] [rpm] [km/h]
shifting
reference value reference value
Throttle output [%] 0 – 20 20–80 80–100 0 – 20 20–80 80–100 0 – 20 20–80 80–100
(+) side pulse count X5 589 589 589 1,689 1,689 1,689 5.6 5.6 5.6
Shift-up
1sto2nd
(+) side pulse count <5 611 611 611 1,752 1,752 1,752 5.8 5.8 5.8
2ndo3rd 1,016 1,016 1,016 1,559 1,559 1,559 9.7 9.7 9.7
(-) side pulse count X20
& modulation clutch
output shaft speed sig- 957 957 957 790 790 790 9.1 9.1 9.1
nal
ON (1,450 rpm or more)
(-) side pulse count <20
& modulation clutch
output shaft speed sig- 908 908 908 749 749 749 8.7 8.7 8.7
nal
Shift-down
3rdo2nd ON (1,450 rpm or more)

Modulation clutch out-
put shaft speed signal
109 109 109 90 90 90 1.0 1.0 1.0
OFF (less than 1,450
rpm)
Modulation clutch out-
put shaft speed signal
OFF (less than 1,450 873 873 873 721 721 721 8.3 8.3 8.3
rpm) oON (1,450 rpm
or more)
After directional change
2ndo1st 436 436 436 669 669 669 4.2 4.2 4.2
with gear shift lever at 1
a When the 3rd gear speed cut option is selected, the gear speed does not shift to 3rd. (The gear
speed switches between 1st and 2nd speed.)
2) Normal automatic non-shifting time (common for forward and reverse)

Disapproved shift
time
Gear shifting Applicable conditions [sec]
1sto2nd – 2.00
Shift-up
2ndo3rd – 2.00
Modulation clutch out-put

shaft speed signal 2.00
ON (1,450 rpm or more)
Modulation clutch output
shaft speed signal
Shift-down
0.00
OFF (less than 1,450
3rdo2nd
rpm)
Modulation clutch output
shaft speed signal
OFF (less than 1,450 2.00
rpm) oON (1,450 rpm or
more)
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Electrical system
3) Auto shift operation table
WA1200-6 10-323
Electrical system
2. Change of auto shift/manual (change of traveling mode)

1) Actual gear speed and shifting range display when shift mode is switched between manual and auto
shift mode
1] Change from auto shift to manual
Actual gear speed Not shifted.
Actual gear speed
Shifting range display
2nd speed if all speed clutches is set to neutral for troubleshooting.
a Change of the actual gear speed does not apply to the prevention of overrun and the downshift
inhibiter control.
2] Change from manual to auto shift

Gear speed corresponding to the travel speed (evaluated by the upshift point
Actual gear speed
of automatic transmission).
Shifting range display The gear speed before change
2) Initial status when the power is ON

1] Actual gear speed
Forcibly set to neutral until direction lever is set to neutral and engine speed
(1) Start-up
exceeds 500 rpm.
Gear speed corresponding to the shift range and the travel speed.
2nd speed when the auto shift mode is selected before the starting switch is
(2) After (1) in AJSS manual turned to OFF position.
(During traveling, if gear shifting is performed with direction control at neutral,
gear speed shifts up to the gear speed corresponding to the travel speed.
Gear speed corresponding to the shift position and the travel speed.
(3) After (1) in AJSS auto
(In stop status, 1st speed when the lever position is the 1st speed and 2nd
shift
speed when lever position is 2nd or 3rd speed.)
2] Shifting range display

Shifting range selected before starting switch is turned to OFF position.
Selected shifting range if upshift/downshift is performed.
(4) In AJSS manual
2nd speed if auto mode is selected before starting switch is turned to OFF
position.
Shifting range before starting switch is turned to OFF position.
(5) In AJSS auto shift 2nd speed if manual mode is selected before starting switch is turned to OFF
position.
3] Traveling mode (auto shift/manual)

q Depends on the input signal.
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Electrical system
3. Solenoid output when FNR is changed

Monitor the FNR signal full time. This supersedes other controls.
Manual mode Auto shift mode
AJSS knob solenoid output AJSS knob solenoid output
switch F R Gear speed before N switch F R 2nd speed (*)
F Q F Q
N Q N Q
R Q R Q
(*): 1st speed when the shifting range position is
[1]
4. Shifting pattern
a Follows the specification when the overrun prevention function is activated.
1) Manual shift pattern
WA1200-6 10-325
Electrical system
2) Auto shift pattern

q The upshift/downshift switch functions as the shifting range selector.
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Electrical system
5. Speed clutch change function in N (neutral)

1) Function
When traveling on a downhill with direction control at N position, this function prevents overrun in the
transmission and prevent overrun of the engine when the FR cut is recovered.
2) Shifting specification
q Change control in N is started 0.5 second later (settings can be made uniformly with data) when the
lever position is N.
In other words, set the speed non-shifting time after FoN and RoN. Maintain the speed gear
before change to N during the time from FoN and RoN operations to non-shifting time.
q When the lever position is F or R during the non-shifting time, cancel the non-shiting time in N and
perform shifting for the speed unit.
Fig. 1 Upshift/downshift conditions
q In manual mode, the transmission upshifts to the gear speed selected using speed switch.
In manual mode, do not downshift to the lower gear than the speed switch position.
q Non-shifting time for N is 0 second.
<Example>
If shifting modulation to the 2nd speed is performed and when the shifting conditions to the 3rd
speed are satisfied, the gear speed shifts to the 3rd speed immediately.
WA1200-6 10-327
Electrical system
3) In FR cut recovery, action when the FNR switch position is F or R.

1] In directional selection
Follow the directional protection function.
2] FR cut recovery, FoNoF, RoNoR
Give priority to the downshift protection control. In auto mode, perform shifting to the gear speed
determined by the auto shift operation table.
3] Action for selection of 3rd speed cut option
If the option is selected, the upshift function to the 3rd speed with protection is activated.
a If N is set due to a failure, shifting in N should be prohibited.
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Electrical system
6. Downshift protection
q Downshift operation when the machine is traveling at overrun speed
q Control specification
Downshift protection control (common to auto shift and manual shift)
1) Protection condition
1] When protection conditions (hateched area) in Fig. 1 are satisfied, downshift command is not output
and warning signal is output (current gear speed output is maintained).
2] After operation of NoF or R (FoNoF, RoNoR)
When the current gear speed does not correspond to the target gear speed and the protection
conditions in Fig. 1 are satisfied, downshift command is not output (current gear speed output and
warning signal is output).
3] When operation NoF or R (FoNoR, RoNoF) is completed and the current gear speed does not
correspond to the target gear speed after completion of downshift control after directional shifting,
and when the protection conditions in Fig. 1 are satisfied, downshift command is is not output
(current gear speed output and warning signal is output).
Downshift operation is:
q [1] Downshifting with the downshift switch
q [2] Downshifting with the kickdown switch
When protection in [2] of downshifting is activated, give output of the protection warning and ignore
the downshifting.
If kickdown in [2] is performed again during protection, accept the operation and evaluate the
protection condition again at the time. If protection conditions are not satisfied, perform kickdown
and cancel the warning with previous protection.
2) Protection cancellation condition
q When cancellation conditions (hatched area in Fig. 1) are satisfied, stop the warning and give down-
shift output.
q When protection in [2] of downshifting is activated, cancellation conditions are satisfied 3 seconds
later. Do not activate downshifting at the time of cancellation. (Downshifting is not memorized.)
If kickdown in [2] is performed again during protection, reset the counting of 3 seconds again.
q If the difference between the target gear speed and the current gear speed is 2 speeds or more,
perform downshifting to the gear speed when the protection condition to the gear speed one lower
than the current gear speed is cancelled.
(Excluding operation in [2])
<Example>
When the current gear speed is the 3rd, the target gear speed is 1st (range display 1st) and the protec-
tion conditions for downshifting to the 2nd speed are satisfied.
When the protection cancellation conditions for downshifting to the 2nd speed, start downshifting to the
2nd speed. When the protection cancellation conditions to the 1st speed are satisfied later, stop the
warning and start downshifting output to the 1st speed.
3) Protection cancellation condition: For the following cases, stop the protection warning output and
return to normal control.
q When the input command corresponds to the output command with the AJSS switch operation
q When shifting more than the output command with the AJSS switch operation is selected
4) Warning function specification
The buzzer given with the protection function is the same as the transmission protection in FR change.
5) Action for directional change (FNR)
When the direction (FNR) is changed, give priority to the directional protection control for implementa-
tion.
WA1200-6 10-329
Electrical system
Fig. 1
(*1): When the transmission output shaft speed is 1,527 rpm or more, and the downshift switch is accepted
twice.
7. Direction protection function

1) Auto mode and manual mode
1] In auto mode
Fig. 1
(*1): When the shift position is at the 2nd or 3rd speed

(*2): When the shift position is at the 1st speed
(*3): Recovery from kickdown
(*4): FR is changed while maintaining the 1st speed.
q Change F-R and give warning according to Fig. 1. Shifting of the speed clutch is selected cor-
responding to the travel speed (according to the shifting point in Fig. 1). Then, downshift is per-
formed to the 2nd or 1st speed corresponding to the travel speed.
(No speed condition of the modulation clutch in "1. List of normal automatic shifting and variable
shifting time")
q Perform shifting to the gear speed which is the maximum gear speed determined for each speed
position.
q The end condition of the warning is 3 seconds or satisfactory upshift condition, whichever is lon-
ger.
<Example>
When the speed position switch is at the 1st speed, F1, shifting of 14 km/hoR is performed
Shifting of F1oR3oR2oR1 is performed.
10-330 WA1200-6
Electrical system
2] In manual mode (speed position switch before shifting is the 2nd or 3rd)
Fig. 2
(*1): When the range evaluation is the 1st speed

(*2): FR is changed while maintaining the 1st speed.
q Change F-R and give warning according to Fig. 2.
q Shifting of the speed clutch is selected corresponding to the travel speed (according to the shift-
ing point in Fig. 2). Then, downshift is performed to the speed position corresponding to the trav-
el speed.
(No speed condition of the modulation clutch in "1. List of normal automatic shifting and variable
shifting time".)
q The end condition of the warning is 3 seconds or satisfactory upshift condition, whichever is lon-
ger.
2) Inhibition time setting
q Set the inhibition time after directional change (from start of shifting). Do not change the speed dur-
ing this time.
(Both for auto mode and manual mode)
q Kickdown and upshift/downshift are not accepted during the inhitibition time.
: Kickdown operation oIgnore operation.
: Upshift/downshift operation o Ignore operation.
q Inhibition time: 2 seconds
<Example>
When auto mode, F2, 15 km/hoR shifting
Shiftingo of F2oR3oR2 is performed. Counting of the inhibition time is started from start of R3
shifting.
3) Upshift permission condition after directional protection control
Downshift end condition after the speed shifting gear is changed
1] Permission condition
After the inhibition time
and (the machine moving direction corresponds to the F/R switch position or the machine moving
direction recognition = stop status)
2] Speed gear selected after completion
q In auto mode:
Select it from the downshift protection control table and the auto shift table.
q In manual mode:
Select it from the downshift protection control table and the speed position switch.
4) When the 3rd speed cut option is selected
Even if the 3rd gear cut option is selected, the protection function can upshift to the 3rd gear speed.
5) Status notification to KOMTRAX Plus
Conditions are notified upon request from KOMTRAX Plus.
q Status 0: Other than below.
q Status 1: Caution is given regardless of auto or manual (hatched areas in Figs 1 and 2).
WA1200-6 10-331
Electrical system
Engine control 10-3 2 6] The throttle level once set can be cleared
1. Engine throttle control with the conditions below.
q For the engine control, the transmission con- q Set the throttle lock function switch to
troller sends the lower limit of throttle position the OFF position.
to the engine controller through the NET or
communication. The engine controller uses q Turn the starting switch to OFF posi-
the value to control the engine. tion.
q The priority of signals used for the engine 7] When the throttle lock SET/ACCEL
control by the engine controller is as follows: switch or throttle lock RESUME/DECEL
a) Throttle lower limit switch are kept pressed for 0.5 second or
V more, acceleration or deceleration func-
b) Input signal value from throttle pedal tion is activated, allowing for fine setting
(Detected by engine controller) of throttle level.
However, if the throttle lock SET/ACCEL
2. Throttle signal output value setting switch and throttle lock RESUME/DECEL
q The throttle signal value sent to the engine switch are pressed at the same time, no
controller is expressed in by the throttle lower control is available.
limit. 8] In the setting with auto deceleration func-
q The throttle lower limit is set by the throttle tion, if following conditions are satisfied,
lock function. the throttle lock function is canceled
q If the throttle lower limit value is not set by the temporarily; the transmission neutral
throttle lock function, the value is set to 0 % status continues for 4 seconds or more,
which is the default value. the work equipment lever neutral status
continues for 4 seconds or more, in above
3. Throttle lock function duration, the throttle lock SET/ACCEL
1) Outline switch and the throttle lock
1] The throttle lock function switch is the RESUME/DECEL switch are not oper-
alternate switch of 3 positions. When the ated, the travel speed is 5 km/h or less.
upper part is pressed, the throttle lock is The engine is controlled according to the
activated without auto deceleration. signal from the accelerator pedal. (The
When the lower part is pressed, the function is canceled temporarily similarly
throttle lock is activated with auto deceler- when the right brake pedal is depressed.)
ation. At the neutral position, the throttle 9] In the setting with auto deceleration func-
lock function is disabled. tion, when the throttle lock function is
2] Press the upper part or lower part (acti- canceled temporarily (4] or 8] above), if
vated) of the throttle lock function and the transmission is not at the neutral or
depress the acclerator pedal. When the throttle lock or the work equipment lever
desired engine speed is reached, press is not at the neutral position, the throttle
the throttle lock SET/ACCEL switch to set lock control status is automatically recov-
the throttle level. ered.
If the accelerator opening is smaller than
the determined throttle level, the setting is
not changed.
3] If the accelerator pedal is depressed
further than the determined throttle level,
the signal (larger value) of the accelerator
pedal has priority.
4] When the right brake pedal is depressed,
the throttle lock function is cancelled
once. (The engine is controlled by the
depression stroke of the accelerator
pedal.)
(The depression of the right brake is
determined when the right brake switch is
ON.)
5] When the throttle lock RESUME/DECEL
switch is pressed, the throttle level
returns to the set throttle level.
10-332 WA1200-6
Electrical system
List of
Throttle lock Throttle lock
compo- Throttle lock func- Right brake pedal Throttle lock dis-
SET/ACCEL RESUME/DECEL
nents tion switch Control switch play lamp
switch switch
Switch
Alternate Momentary proximity
composi- Momentary seesaw switch In-switch LED
3 position switch switch
tion
Brake operation
Performed
Switch ON(24 V) ON(GND) (GND)
through electrical
theory OFF(OPEN) OFF(OPEN) Brake not operated
circuit
(OPEN)
Resume function
When the upper
Throttle position set- When this switch is
part of this swtich
ting function pressed while the throt-
is pressed, "With-
The throttle amount is tle lock function is can-
out throttle lock
stored when it is ON celled with the right
auto deceleration
(lock accelerator open-brake pedal (cancella-
function" is set.
ing ratio) tion), the throttle lock
When the lower
It is controlled with the
function is recovered. When the right brake
part of this swtich
edge of the input sig- It is controlled with the pedal is depressed, Lights when the
is pressed, "With
Function nal. edge of the input sig- the throttle lock func- throttle lock func-
throttle lock auto
nal. tion is temporarily tion switch is ON.
deceleration func-
Accelerator function Deceleration function cancelled.
tion" is set.
When the switch is When the switch is
pressed and held for pressed and held for
When the middle
0.5 seconds, the throt- 0.5 second, the throt-
part of this switch
tle opening set value tle opening set value
is pressed, the
rises in accordance lowers in accordance
throttle lock func-
with the time the switch with the time the switch
tion is OFF.
is pressed. is pressed.
WA1200-6 10-333
Electrical system
2) Throttle lock function status transition
q Creation of lock accelerator opening for each status (Lock accelerator opening: Throttle lock level
set by the throttle lock set switch)
1] Status with throttle lock function disabled (default at key ON)
Lock accelerator opening iActual accelerator opening
2] The throttle lock function is enable and the opening is not determined. (Status immediately after the
throttle lock function is started)
3] The throttle lock function is enabled, the opening is determined and the actual throttle lcck status is
active. (Status of throttle lock function in operation) Control the accelerator opening with the actual
accelerator opening or the SET switch and the RESUME/DECEL switch.
(Lock accelerator opening i Refer to the throttle lock time chart in 3) 1] and 2].)
4] The throttle lock function is enabled, the opening is determined but the status is temporarily
cancelled by the brake switch or auto deceleration.
(Temporary cancellation status of throttle lock)
Memory lock accelerator opening i Lock accelerator opening just before
With RESUME/DECEL switch:
Lock accelerator opening i Memory lock accelerator opening (resuming throttle lock)
With SET/ACCEL switch:
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Electrical system
3) Calculation of final accelerator opening in the throttle lock function

The throttle lock function set the lower limit of the throttle level.
a Refer to "2. Throttle signal output value setting".
1] Details of accelerator function
q When the accelerator switch is kept pressed during throttle lock, the lock accelerator opening is
increased at the rate of 10% per second after 0.5 second.
2] Details of deceleration function

q If the deceleration switch is being pressed while the throttle is locked for 0.5 seconds, the set
lock accelerator open position starts to be lowered at a rate of 10% in 1 second.
q Acceleration and deceleration switch operation exceeding 100% or less than 0% is invalid (input
is ignored).
4. Engine control torque curve

a The engine performance curve is selected
automatically according to the load on the
machine.
WA1200-6 10-335
Electrical system
Modulation clutch (MOD/C) 10-3 6

1. Control function
Modulation clutch control
Travel speed control function
Driving force control function
Tire slip control function
Wall digging prevention control
Dump truck approach control function
Emergency operation switch
2. Modulation clutch control 2) Driving force control function

The modulation clutch control has the following The driving force determined with the driving
functions: force control dial can be reduced to the
1) Travel speed control function approriate value. In this way, slip of tires can
This function can keep the travel speed be prevented on a slipper road such as clay
below the maximum travel speed set with the (tuff loam), mud, etc. An operator can work
travel speed control dial. Accordingly, if it is without paying attention to control of the
used during dump truck approach, the accelerator.
forward travel speed is restricted and the With the driving force control dial position,
travel speed is kept low without operating the the maximum driving force can be changed
brake, thus the operator can work easily. from 20% to 100%.
It can be operated with the travel speed <Operating conditions>
control ON/OFF dial only when necessary. q The transmission gear speed is F1.
<Operating conditions> q Flat (See “3. Wall cutting prevention con-
q The travel speed control ON/OFF dial is trol”)
ON. q During digging work
q Only when the transmission gear speed is 3) Tire slip control function
F1 or F2 When the driving force is reduced with the
q Travel speed 1.5 km/h or more driving force control function and slip of tires
The maximum travel speed can be set as still occurs, the driving force can be reduced
follows with the transmission gear speed along with detection of tire slip to minimize
and the travel speed control dial position. the slip level.
Gear speed Maximum travel <Operating conditions>
speed q When tire slip option is enabled
When the 1st 1.5–7 km/h q The transmission gear speed is F1.
speed is selected q No operation of work equipment.
When the 2nd 1.5–12 km/h
speed is selected
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Electrical system
3. Wall digging prevention control (work equip- q If the transmission controller detects power
ment protection control) supply by direct connection using the emer-
To prevent abnormal load on the work equip- gency operation switch, the transmission
ment (bucket cylinder) in wall digging, the driving controller stops the following controls.
force is reduced by slipping the modulation 1) Dial driving force control
clutch to protect the work equipment. 2) Dial travel speed control
a This function can be turned ON/OFF with the 3) Tire slip prevention control
option setting of the multi monitor. It functions 4) Wall digging prevention control
only when it is ON. 5) Pressure reduction control in FR shifting
a Status notification to KOMTRAX Plus 6) Engine start assisting function
Conditions are notified upon request from 7) Modulation clutch solenoid, disconnection,
KOMTRAX Plus. short-circuit failure
q Status 0: Other than below. 8) Dump truck approach control
q Status 1: In buzzer sounding
ECO lamp
4. Dump truck approach control function q The ECO lamp lighting condition of the mon-
This function controls the modulation clutch itor panel is evaluated by the transmission
automatically to increase the bucket rising speed controller and it is sent through communica-
and restrict the forward travel speed. tion.
By this, the dump truck approach distance can Lighting condition:
be shortened without operating the brake, thus q Throttle lock opening setting Z80%
the operator can work smoothly. q Accelerator pedal opening setting Z80%
q When E mode is selected
5. Emergency operation switch (When E mode is selected for output to the
q The modulation clutch is controlled by EC- engine controller)
MV. If a failure of the electrical system includ- q Continued for 0.5 second.
ing controller occurs, the machine cannot be
operated. Lighting OFF condition:
q For this purpose, a circuit to connect the q When the lighting conditions are not satisfied
modulation clutch with the emergency opera-
tion switch is provided.
a When the controller command current to
E-POCV is increased, the hydraulic pressure
is increased and the modulation clutch is di-
rectly connected. (It is disconnected when
the engine is in stop.)
a For a failure of a solenoid valve, the emer-
gency escape plate for E-POCV is provided.
WA1200-6 10-337
Electrical system
Transmission controller 10-3 8
10-338 WA1200-6
Electrical system
Input/output signal
CN-L02 [DEUTSCH-24P]
Input Input
and out- and out-
put put
signals signals
1 Angle sensor (L.R) rolling Input 13 Throttle lock with Auto decel SW Input
2 Left brake press sensor Input 14 Speed limit dial Input
3 Traction dial Input 15 NC Input
4 GND_SIG_D 16 PWR OUT_SENS Output
5 Manual/Auto SW Input 17 NC Input
6 Startor switch (ING-C) Input 18 R brake press sensor Input
7 Angle sensor (F.R) pitching Input 19 Throttle lock without Auto decel SW Input
8 Mod/C oil press sensor Input 20 T/M temp. sensor 2 Input
9 T/M oil temp. sensor Input 21 GND_SIG_A
10 GND_SIG_D 22 PWR_OUT_5V_0 Output
11 Speed limit ON/OFF SW Input 23 NC Input
12 Mod/C direct signal Input 24 F brake press sensor Input
CN-L03 [DEUTSCH-40P(1)]
Input Input
and out- and out-
put put
signals signals
Input/out
1 NC Output 21 NC
put
Input/out
2 ECMV fillSW: Mod/C Input 22 COMM_CAN_L
put
Input/out
3 ECMV fill SW: 3rd Input 23 NC
put
4 NC Input 24 PWR_CTR_EXT Input
5 AJSS shift down (NC) Input 25 AJSS shift up (NC) Input
6 Parking brake signal Input 26 Direction lever: N Input
7 ECMV fill SW: 1st Input 27 ECMV fill SW: F Input
8 NC Output 28 (N)MODE Input
9 NC Output 29 GND_SIG_P
10 Engine rev signal Input 30 Mod/C speed sensor Input
11 NC Output 31 NC
Input/out
12 NC 32 COMM_CAN_H
put
Input/out
13 ECMV fill SW: 2nd Input 33 NC
put
14 NC Output 34 NC
15 AJSS shift down (NO) Input 35 AJSS shift up (NO) Input
16 Direction lever: R Input 36 Direction lever: F Input
17 ECMV fill SW: R Input 37 Tire speed sensor (FL) Input
18 NC Output 38 S/T lever lock pressure SW Input
19 NC Output 39 GND_SIG_P
20 Speed sensor Input 40 NC Input
WA1200-6 10-339
Electrical system
CN-L04 [DEUTSCH-40P(2)]
Input Input
and out- and out-
put put
signals signals
2 PWR_IN_BRY Input 22 PWR_IN_BRY Input
3 GND_ACT 23 GND_ACT
4 NC Output 24 PWR_CTR_KEY Input
5 ECMV: F clutch Output 25 ECMV: 1st clutch Output
6 ECMV: 2nd clutch Output 26 NC Output
7 F bypass solenoid Output 27 1st bypass solenoid Output
8 T/M cutoff indicator Output 28 NC Output
9 (E)MODE TEST Input 29 RESUME/DECEL SW Input
10 T/M cutoff ON/OFF SW Input 30 Kick down SW Input
12 PWR_IN_BRY Input 32 GND_PWR
13 GND_ACT 33 GND_PWR
14 PWR_CTR_KEY Input 34 PWR_OUT_5V_1 Output
15 ECMV: R clutch Output 35 NC Output
16 ECMV: 3rd clutch Output 36 ECMV Mod/C Output
17 R bypass solenoid Output 37 R drain solenoid Output
18 Speed limit indicator Output 38 NC Output
19 SET/ACCEL SW Input 39 Right brake SW Input
20 T/M cutoff set SW Input 40 (P) MODE TEST Input
10-340 WA1200-6
Electrical system
Engine starting circuit
Engine starting circuit 10-341
Function 10-341
q The safety on engine startup is secured by em-
ploying the neutral safety circuit in which the en-
gine cannot be started except when forward and
reverse switch and joystick steering control lever
are in N (neutral).
q The machine employs the pre-lubrication func-
tion which, when the starting switch is put in
START position, first circulates the engine oil to
increase the oil pressure and then starts the en-
gine.
WA1200-6 10-341
Electrical system
Engine starting circuit
Operation 10-342
q When the starting switch is put in the ON posi- q The engine starts up, and the alternator starts to
tion, the current flows from the starting switch generate and output power from terminal B. At
terminal BR to the battery relay to close the con- the same time, terminal L generates the same
tact point of the battery relay. This supplies pow- voltage as the one on terminal B and the current
er to the machine. flows in terminal 2 in the safety relay to make the
q When the directional switch is put in the N (neu- safety relay contact point open and shut off the
tral) position the current flows in the coil in the power supply to the starting motor.
neutral relay to make the contact points 5 and 3 Note that the current from alternator terminal L is
conductive in the neutral relay. supplied to the service meter, etc. as the signal
On the other hand, when the joystick steering indicating that the engine is running.
control lever is in N (neutral), contact points 6 q When the forward and reverse switch is in N
and 3 are conductive in the steering neutral (neutral) and the joystick steering control lever is
relay. in other than N (neutral), the neutral relay and
Here, when the starting switch is set to the steering neutral relay shut off the circuit and the
START position, the current flows as follows: engine does not start.
q The current flows from battery (+)o to starting
switch terminal B o starting switch terminal C o
neutral relay terminals 5 and 3 o steering neu-
tral relay terminals 6 and 3 o pre-lubrication tim-
er terminal 3 to close the contact point of the
pre-lubrication timer itself. Then, the current
flows from battery (+)o to battery relay o pre-lu-
brication starter to circulate the engine oil.
q When the oil is supplied to the whole engine and
the oil pressure increases, the contact point of
the pre-lubrication oil pressure switch becomes
"open", and the pre-lubrication timer opens its
contact point based on this signal.
This shuts off the current to the pre-lubrication
starting motor to terminate the pre-lubrication.
q The current flows between the pre-lubrication
timer terminal 5 and safety relay terminal 1 sev-
eral seconds after the pre-lubrication is terminat-
ed, the contact point of safety relay is closed,
and the power is supplied to the pre-lubrication
and conventional starting motor.
q In this case, the current flows in both holding and
pull-in coils in the starting motor to try to close
the contact. At the same time, the current flows
in the motor body through the pull-in coil, so the
starting motor starts to rotate slowly.
q When the starting motor turns slowly and engag-
es with the gear of the engine, the contact point
of the starting motor is closed by the suction
power of the pull-in coil, so the starting motor
starts to turn fast and the engine starts up.
Until the engine starts, keep the starting switch
key in the START position.
Here, the pull-in coil has no electricity, but the
current flowing in the holding coil keeps the
contact point of the starting motor in the closed
condition.
10-342 WA1200-6
Electrical system
Engine stopping circuit
Engine stopping circuit 10-343
Operation 10-343 Emergency engine stop switch 10-343

q When the starting switch is turned OFF, the sig-
nal from the starting switch terminal ACC stops Function 10-343
the signal sent to the electronic engine governor q When the emergency-stop of the engine is re-
controller of Cummins Engine, and the fuel sup- quired on engine startup, the emergency engine
ply to the engine stops to stop the engine. stop switch is operated to stop the fuel supply to
When the engine speed decreases, the power the engine and by cutting off the signal from the
supply from alternator terminal L stops as well as starting switch terminal ACC to the electronic en-
the power supply from the alternator terminal B, gine governor controller of Cummins Engine,
and the signals sent to service meters, etc. then, the engine stops.
during the engine operation stop.
Also, the power supply to the battery relay from
starting switch terminal BR stops and the contact
point of the battery relay becomes open to stop
the power supply to the machine.
WA1200-6 10-343
Electrical system
q Five emergency engine stop switches are installed on the machine.

On the right and left sides of rear frame: 2 places
Near the rear elevating ladder: 2 places
On the front of right console box in the cab: 1 place
10-344 WA1200-6
Electrical system
Battery disconnect switch 10-345 * The figure shows a left battery box
q When the battery disconnect switch is equipped
and the switch is turned OFF (the contact is
opened), the starting switch B terminal, each
controller, and other unswitched power supplies
are completely shut off and the condition of the
machine is the same as when the battery is not
connected.
q The battery disconnect switch is usually used as
a substitute for removing off the cable from the
negative terminal of the battery when the ma-
chine is stored for a long time (a month or lon-
ger), when the electrical system is repaired, or
when electrical welding is performed.
When the battery disconnect switch is turned off,
all the electrical system of the machine is inoper-
ative.
q The clocks of the monitor and radio, and recep-
tion preset memory of radio is lost, and they
need to be set again when using them.
q The room lamp, step lamp, hazard lamp, etc.
cannot be used either.
q To store the data VHMS is powered by the bat-
tery just after the starting switch is turned OFF.
So, to turn OFF the battery disconnect switch,
first check the lights-out of the indicators for the
connector for downloading VHMS and down-
loading switch (1) on the left side of rear frame
and the lights-out of the indicators for VHMS op-
eration indicators located next to the battery dis-
connect switches (2) mounted on the right and
left battery boxes. When the battery disconnect
switch is turned OFF while any one of indicators
still lights up, VHMS data may disappear after
the starting switch is turned ON last time. (The
memory of the information necessary for ma-
chine setting is not lost)
WA1200-6 10-345
Electrical system
Important
Never turn OFF battery disconnect switch (2) while
the engine is running or immediately after the en-
gine is stopped.
If the battery disconnect switch is turned off while
the alternator is generating power, the generated
power has noplace to go, leading to overvoltage in
the electrical system of the machine, which may
cause serious damage to the electrical system in-
cluding electrical equipment or controller, etc.
Starting auxiliary connector
q A start auxiliary connector in compliance with
SAE J1283 is available as an optional part for
this machine.
q For usage and precautions of the start auxiliary
connector, refer to the Operation and Mainte-
nance Manual.
10-346 WA1200-6
Electrical system
Electric parking brake control
Electric parking brake control 10-347
Outline 10-347
q The parking brake is a wet multiple disc brake 1. Parking brake switch
built in the transmission. When the parking brake 2. Parking brake emergency release switch
solenoid valve is live with electricity, the oil pres- 3. Parking brake display switch
sure from the transmission pump is applied to 4. Accumulator
the parking brake cylinder to release the parking 5. Emergency brake switch
brake. In contrast, when the current is shut OFF, 6. Parking brake solenoid valve
the oil pressure is shut off from the transmission 7. Parking brake emergency release solenoid valve
pump, the oil pressure in the parking brake is 8. Neutralizer relay
drained through the parking brake valve, and the 9. Parking safety relay
force of spring activates the parking brake.
WA1200-6 10-347
Electrical system
Function 10-348
1. Activating and releasing parking brake 6. Parking brake emergency release solenoid
With the parking brake switch. valve
When the oil pressure cannot be supplied from
2. Automatic parking brake the transmission pump due to a failure, etc., the
When the engine is stopped (starting switch is parking brake emergency release switch on the
turned OFF), the parking brake works automati- operator's seat activates the emergency release
cally to prevent an accident while an operator is solenoid valve to flow the accumulator charge
leaving the seat. pressure in the brake piping into the parking
brake cylinder and release the parking brake.
3. Emergency brake
When the hydraulic pump pressure of the brake
decreases and braking force is reduced due to
the damage of the hydraulic circuit, etc., the
parking brake works automatically to act as an
emergency brake.
4. Parking brake safety

After the automatic parking brake works, it is
dangerous if the parking brake is released only
by turning ON the starting switch. For securing
safety, the brake cannot be released unless the
parking brake switch is turned ON (brake
applied) once after the starting switch is turned
ON.
5. Neutralizer
When the machine travels while the parking
brake works, the parking brake is often burned
off. The caution lamp and caution buzzer warn
you of a wrong operation, and at the same time,
the transmission is forcibly put in neutral position
while the parking brake works. However, taking
into account that the neutral position prolongs
the braking distance while the emergency brake
is working and taking into account an escapa-
bility when stopped in the prohibited place (in the
crossing), the transmission cannot be put in
neutral when the emergency brake is activated.
10-348 WA1200-6
Electrical system
Operation 10-349
1. When the starting switch is turned OFF 10-349
q When the starting switch is turned OFF, the bat-

tery relay opens, so the current does not flow in
the parking brake circuit. Therefore, if the start-
ing switch is turned OFF, regardless of whether
the parking brake switch is ON (start) or OFF (re-
lease), the current does not flow into the parking
brake solenoid valve and the parking brake
works. (automatic parking brake).
WA1200-6 10-349
Electrical system
2. When starting switch is turned ON 10-350

2-1 When the parking brake switch is turned ON before the starting switch is turned ON 10-350
q (1) As the current flows from battery (+) o start-

ing switch o battery relay coil o ground, the bat-
tery relay becomes closed. Then, (2) the current
flows from battery (+) o battery relay o parking
brake switch terminals 5 and 6 o parking safety
relay terminals 1 and 2 o ground.
Thus, the parking safety relay is activated to
close the safety relay terminals 3 and 5.
q Now, (3) the circuit is created from battery (+) o
battery relay o parking safety relay terminals 5,
3 o parking safety relay terminals 1 and 2 o
ground, and then, this circuit (3) is the parking
safety relay circuit until the starting switch is
turned OFF.
q Now that, as the current does not flow into the
parking brake solenoid valve in this condition,
the parking brake is active.
q Also, in this condition, the circuit between termi-
nals 3 and 5 of neutralizer relay is open and the
transmission controller put the transmission in
neutral condition.
10-350 WA1200-6
Electrical system
2-2 When the parking brake switch is turned OFF before the starting switch is turned ON 10-351
q (1) As the current flows from battery (+) o start-

ing switch o battery relay coil o ground, the bat-
tery relay becomes closed. However, in this
case, the parking brake switch is turned OFF (re-
lease), so the parking safety relay does not work.
Therefore, as the current does not flow into the
parking brake solenoid valve, even if the starting
switch is turned ON after the automatic parking
brake is activated, the parking brake is not re-
leased automatically.
q Also, as the current does not flow into the trans-
mission controller, the machine does not move.
WA1200-6 10-351
Electrical system
3. When the parking brake switch is turned OFF (release) 10-352

When the parking brake switch is turned OFF after the starting switch is turned ON 10-352
q When the parking brake switch is turned OFF

(release), the circuit is connected between the
terminals 3 and 4 in the parking brake switch and
the parking brake safety relay is working, so (1)
the current flows from battery (+) o battery relay
o parking brake safety relay o parking brake
switch and to the circuits (2) and (3).
(2) The circuit from emergency brake switch o
parking brake solenoid valve o ground becomes
active, and the parking brake is released.
(3) At the same time, the signal flows from three
neutralizer relay terminals to the transmission
controller and the machine becomes possible to
travel.
10-352 WA1200-6
Electrical system
4. When the parking brake switch is turned ON (activate) 10-353
q When the parking brake switch is turned ON af- q Also, at the same time, as the neutralizer relay is
ter working while the parking brake switch is restored, the circuit between 3 and 5 becomes
turned OFF (release), the circuit is shown in the open, the signal does not flow from three neutral-
figure above. izer relay terminals to the transmission controller
q As the current does not flow in the parking brake and the transmission becomes neutral.
solenoid valve, the oil pressure applied from the In this manner, by putting the transmission in
transmission pump to the parking brake cylinder neutral while the parking brake is working, the
is shut off, and at the same time, the pressurized parking brake cannot be burned off even if the
oil in the parking brake cylinder is drained machine travels while the parking brake is
through the parking brake valve, so the force of applied.
spring activates the parking brake.
WA1200-6 10-353
Electrical system
5. When the oil pressure of main brake decreases (emergency brake is activated) 10-354
Operation 10-354
q When the oil pressure of the main brake line de- q Therefore, the signal flows into the transmission
creases, the emergency brake switch installed to controller and the transmission clutch becomes
the accumulator becomes open. connectable. Thus, the engine brake is also
Therefore, the current does not flow in the available when the emergency brake is working,
parking brake solenoid valve, so the pressurized so the braking distance can be shorter. In case
oil in the parking brake cylinder is drained and the machine needs to be moved while the emer-
the parking brake is activated. But, in this case, gency brake is working (in the case that the
unlike when the parking brake switch is turned emergency brake is activated when traveling a
ON, the coil in the neutralizer relay is live with crossing), it becomes possible to move the ma-
electricity. chine by operating the transmission switch.
10-354 WA1200-6
Electrical system
6. Emergency-releasing parking brake 10-35
Operation 10-35
q When the machine stops due to the problem of
the engine, etc., the oil pressure from the trans-
mission pump to the parking brake cylinder is
shut off to activate the parking brake. In this
case, the oil pressure of the main brake line is
accumulated in the accumulator.
q If the emergency release switch is turned ON
(release) the buzzer sounds. At the same time,
the emergency release solenoid valve is live with
electricity, and the pressurized oil accumulated
in the accumulator in the main brake line flows
into the parking brake cylinder to release the
parking brake.
q Always turn OFF the emergency release switch
in normal condition and after clearing the emer-
gency.
WA1200-6 10-355
Electrical system
Parking safety relay

Neutralizer relay
Emergency brake switch
Parking brake emergency release switch
10-356 WA1200-6
Electrical system
Sensor
Sensor 10-357
Ambient temperature sensor 10-357
1. Power consumption: Max. 0.5 mW
2. Withstand pressure: 0.98 MPa {10 kg/cm2}
3. Detected temperature range (ambient): -30 °C to
120 °C
4. Storing temperature range: -50 °C to 140 °C
5. Performance table
Detected
tempera- -30 -20 -10 0 10
ture ( °C)
Resis-
51.10 30.32 18.58 11.74 7.623
tance (kz)
Detected
tempera- 20 30 40 50 60
ture ( °C)
Resis-
5.077 3.461 2.410 1.712 1.239
tance (kz)
a: Thermal sensor mount diameter: 16 x 15
Function 10-357
This sensor inputs the ambient temperature to the
VHMS controller with a variation of the thermistor re-
sistance.
WA1200-6 10-357
Electrical system
Sensor
Air cleaner clogging sensor 10-358
1. Indicator
2. Spring
3. Adapter
Function 10-358
q The air cleaner clogging sensor is installed to the
air cleaner outlet. If the air cleaner is clogged
and the pressure reaches the specified level
(negative pressure), the caution lamp on the ma-
chine monitor lights up to output a warning.
10-358 WA1200-6
Electrical system
Sensor
Coolant level sensor 10-359
1. Stopper 4. Plug
2. Float 5. Tube
3. Sensor 6. Connector
Function 10-359
q The coolant level sensor is installed to the radia-
tor upper tank. If the coolant level lowers below
the specified level, the float lowers and the
switch is turned “OFF”.
WA1200-6 10-359
Electrical system
Sensor
Battery electrolyte level sensor 10-360
1. Body 3. Filter 5. Pin

2. Connector 4. Packing
Function 10-360
q The battery electrolyte level sensor is installed to
the battery. If the battery electrolyte level lowers
below the specified level, the sensor tip is ex-
posed to air and a signal of voltage change is
generated. The signal is sent to the machine
monitor to give the warning.
10-360 WA1200-6
Electrical system
Sensor
Fuel level sensor 10-361
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
Function 10-361
q The fuel level sensor is installed to the side of the
fuel tank. The float moves up and down accord-
ing to the fuel level.
The movement of the float operates the variable
resistor through the arm, and the signal is sent to
the machine monitor to indicate the fuel level.
When the machine monitor indicator reaches a
specified position, the caution lamp is lit.
WA1200-6 10-361
Electrical system
Sensor
Accelerator pedal sensor 10-362
1. Pedal Output characteristics 10-362

2. Connector
3. Sensor
Function 10-362
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle val-
idation signal depending on the accelerator ped-
al depressing angle.
Accelerator signal
q The sensor detects the accelerator pedal dis-
placement and the variable voltage is output
from No. 2 pin.
Idling validation signal

q The sensor detects the accelerator pedal opera-
tion. As the accelerator pedal is released, it out-
puts the signal being entered No. 5 pin from No.
4 pin. And as the accelerator pedal is depressed,
it outputs the signal being entered No. 6 pin from
No. 4 pin.
10-362 WA1200-6
Electrical system
Sensor
Resistance for direct connection of modulation clutch 10-363
Function 10-363
q The resistor allows appropriate current to flow to
the ECMV solenoid for modulation clutch when
the modulation clutch direct connection switch is
turned ON.
q No current flows when the modulation clutch di-
rect connection switch is turned OFF.
Resistance: 30 z
WA1200-6 10-363
Electrical system
Sensor
Modulation clutch speed sensor 10-364

Output shaft speed sensor 1 10-364
Output shaft speed sensor 2 10-364
1. Magnet 3. Wiring harness

2. Locknut 4. Connector
Function 10-364
q The modulation clutch speed sensor is installed
between the torque converter and modulation
clutch. The output shaft speed sensors 1 and 2
are installed on the output gear under the trans-
mission. These sensors send pulse signals
based on the rotation signals of the gear to the
transmission controller.
q The transmission controller converts the pulse
signals to the number of rotation (rpm) and trans-
mits it to the machine monitor via the network.
The machine monitor converts the rpm into the
travel speed and displays it.
10-364 WA1200-6
Electrical system
Sensor
Transmission oil filter clogging sensor 10-365
1. Body
2. Tube
3. Connector
A: Pick up port on low pressure side

B: Pick up port on high pressure side
Function 10-365
q The clogging sensor is installed to the filter sec-
tion. If the filter is clogged and the pressure dif-
ference between the lower and higher sides
reaches a specified level, the switch is turned
OFF, and the maintenance caution lamp lights
up. At the same time, the message is displayed
on the character display to warn the problem.
Operating pressure: 275 kPa {2.8 kg/cm2}

Switch method: Differential pressure sliding
piston type
WA1200-6 10-365
Electrical system
Sensor
Modulation clutch oil pressure sensor 10-36

Torque converter, transmission oil pressure sensor 10-36
PPC oil pressure sensor 10-36
1. Sensor
2. Lead wire
3. Connector
1. Accuracy: ±3%(-20 – 110 °C)
2. Consumption current: MAX 20 mA
3. Withstanding pressure: 9.81 MPa (100 kg/cm2)
a: Sensor mount diameter: PT 1/8
Function 10-36
q The sensor inputs the oil pressures of the torque
converter, transmission, and PPC with voltage
signals to the VHMS controller.
q The sensor inputs the oil pressure of the modu-
lation clutch with a voltage signal to the transmis-
sion controller.
10-366 WA1200-6
Electrical system
Sensor
Transmission oil temperature sensor 10-367

Torque converter oil temperature sensor 10-367
Brake oil temperature sensor 10-367
Hydraulic oil temperature sensor 10-367
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
Function 10-367
q The transmission oil temperature sensor senses
the temperature of oil in the transmission case
and the transmission controller uses the temper-
ature to select the electronic modulation temper-
ature table for optimum modulation control
according to the oil temperature.
q The torque converter, brake and hydraulic oil
temperatures are sensed by the mechanical
monitors, are displayed in gauges, and are sent
through the network to the transmission control-
ler.
WA1200-6 10-367
Electrical system
Sensor
AJSS knob 10-368
1. Horn switch: Switch for sounding horn

2. Downshift switch: Change of gear speed (downshift)
3. Upshift switch: Change of gear speed (upshift)
4. Directional switch: Switch to select forward, reverse or neutral
Function 10-368
q Directional selector switch is held at a selected
position. Transmission controller shifts the gear
according to the signal from the directional se-
lector switch.
q Upshift and downshift switches select a circuit
only while the switch is being pressed, and the
transmission controller changes the gear speed
according to the signals.
q The relay is operated and the horn sounds while
the switch is pressed.
10-368 WA1200-6
Electrical system
Sensor
AJSS steering lock switch 10-369
1. Case
2. Tube
3. Connector
Function 10-369
q When AJSS steering lock lever is operated, the
steering pilot pressure circuit is shut off, and the
pilot pressure lowers and the switch is turned to
"OPEN" position.
q Even if the steering lock lever is in the operating
condition the AJSS does not work because the
pilot pressure is low while the engine is not run-
ning, and the condition is the same as the condi-
tion when the steering lock lever is set to LOCK
position.
WA1200-6 10-369
Electrical system
Sensor
AJSS lever angle sensor 10-370

AJSS frame angle sensor 10-370
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function 10-370
q The lever angle sensor is installed to the AJSS
lever in the L.H. console, and frame angle sen-
sor is installed to the follow-up linkage of the ma-
chine rear frame. Data from these sensors are
converted to the lever angle and steering angle
respectively by the work equipment controller.
10-370 WA1200-6
Electrical system
Sensor
Brake oil level sensor 10-371

Brake cooling oil level sensor 10-371
Hydraulic oil level sensor 10-371
1. Connector 3. Float
2. Bracket 4. Switch
Function 10-371
q The sensors are installed on the side of the
brake tank and hydraulic tank respectively.
When the oil level lowers below the specified lev-
el, the float goes down to turn OFF the switch.
WA1200-6 10-371
Electrical system
Sensor
Brake accumulator pressure switch (front/rear) 10-372
1. Case
2. Tube
3. Connector
Function 10-372
q If the brake accumulator oil pressure lowers, the
contact opens, and the caution lamp lights up on
the machine monitor to warn of the fact.
10-372 WA1200-6
Electrical system
Sensor
Stop lamp pressure switch 10-373
1. Case Function 10-373

2. Tube q When the brake pedal is depressed and the
3. Connector brake operating pressure is generated, the pres-
sure switch contact is closed, the relay is operat-
ed and the stop lamp lights up.
Emergency brake pressure switch (front) 10-373

Emergency brake pressure switch (rear) 10-373
1. Case Function 10-373

2. Tube q When the brake accumulator pressure lowers,
3. Connector the switch contact opens. Then, the circuit be-
tween the parking brake switch and parking
brake solenoid is shut off, and the parking brake
operates.
WA1200-6 10-373
Electrical system
Sensor
Parking brake pressure switch 10-374
1. Case
2. Tube
3. Connector
Function 10-374
q When the parking brake is released, oil pressure
is applied to the brake piston. The oil pressure
operates the pressure switch to turn on the park-
ing brake pilot lamp on the machine monitor.
10-374 WA1200-6
Electrical system
Sensor
Kickdown, speed control ON/OFF switches 10-375
1. Switch A (White wiring harness)

2. Wiring harness
3. Connector
4. Knob
5. Switch B (Yellow wiring harness)
Function 10-375 Release

q Switch A (1) installed on knob (4) of the lift arm (in manual shift mode)
control lever is a kickdown switch, and switch B q When the directional switch is in "N" or "R"
(5) is a speed control ON/OFF switch. q When the upshift or downshift switch is pushed
q Switch A (1) installed on knob (4) of the bucket (forward 1st unchanged when downshift switch
control lever is a cancel switch of the load meter, is pushed)
and switch B (5) is a sub total switch. q When the starting switch is turned OFF
q Both switches A (1) and B (5) are automatic re-
turn type whose contact points close only while (in auto shift mode)
an operator pushing the switches. q When the directional switch is "N"
q When the directional switch is changed between
Kickdown switch forward and reverse
Operation 10-375 q When the upshift or downshift switch is pushed
q The kickdown switch is installed on the lift arm q When the travel speed increases
lever. When the switch is pushed while the con- q When the starting switch is turned OFF
ditions of the travel mode, gear speed, and travel
speed are met, the gear speed is shifted down to
1st gear.
q In the manual shift mode, the kickdown switch
works only when the gear speed is forward 2nd.
When the switch is pushed the gear speed is
shifted down to 1st gear.
q In the auto shift mode, when the travel speed is
less than 13 km/h in forward or reverse mode,
the gear speed is shifted down to 1st gear if the
switch is pressed.
WA1200-6 10-375
Electrical system
Sensor
Front brake pressure sensor 10-376

Rear brake pressure sensor 10-376
Hydraulic oil pressure sensor 10-376
Loader pump pressure sensor 10-376
Lift arm bottom pressure sensor 10-376
Lift arm head pressure sensor (load meter) 10-376
1. Sensor 2. Connector
Function 10-376 Operation 10-376

q The sensor is installed to the inlet port circuit for q The oil pressure entering through the pressure
the control valve. The sensor converts the pump inlet port presses the diaphragm of the oil pres-
delivery pressure to voltage and transmit it to the sure sensor, and deforms the diaphragm.
work equipment pump controller. q The gauge layer is provided on the opposite side
of the pressure receiving face of the diaphragm.
The deformation of the diaphragm is sensed in
the change in the resistance and is converted to
the voltage, then is sent to the amplifier (voltage
amplifier).
q The amplifier amplifies the received voltage and
transmits it to the work equipment controller.
q Relational expression of pressure P (MPa
{kg/cm2}) and output voltage (V)

V=0.08 {0.008}xP+0.5
10-376 WA1200-6
Electrical system
Sensor
Communication (ORB: Orbcomm) controller and antenna 10-37
controller 10-37
1. Operating supply voltage: 12 VDC to 30 VDC
2. Size: W 306 x D 175.5 x H 50 (mm)
Mounting position 10-37

Under the operator's seat
Connector part 10-37

CN-ORB1: DRC23-40P
CN-ORB3: Communication antenna cable connec-
tor
Antenna 10-37
1. Type: Helical whip antenna (1)
2. Impedance: 50 z
3. Input terminal: M-P model
4. Length: 165 ± 20 mm
a: Communication antenna mount
Mounting position 10-37

The antenna is installed on top of the pole on the
rear left side of the machine.
Function 10-37
It transmits the data collected and stored by VHMS
controller to the computer center via the communi-
cation satellite.
WA1200-6 10-377
Electrical system
Sensor
VHMS controller related 10-378

a Details for basic precautions and outline, see
"Testing and adjusting"
VHMS controller 10-378

a For details of basic precautions, outlines, meth-
od of sending and receving data, and the proce-
dure for the initial setup, see “ Testing and
adjusting” .
1. Voltage of power supply: DC20V–DC30V
2. Dimension: W272 x D169 x H72 (mm)
Function 10-378
Collect signals from each sensor and machine con-
troller.
q Stores.Also gives commands for transmitting the
accumulated data through the communications
satellite.
10-378 WA1200-6
SEN0547508-00 20-1
WA1200-6
WHEEL LOADER
Shop Manual 2-01
WA1200-6

WA1200-6 60001 and up
20 Standard value table 20-1
WA1200-6 20-1
Contents
Contents 20-2
20 Standard value table
Standard value table ............................................................................................................... 20- 3
Standard value table for engine ........................................................................................... 20- 3
Standard value table for chassis.......................................................................................... 20- 4
20-2 WA1200-6
Standard value table
Standard value table for engine
Standard value table 20-3

Standard value table for engine 20-3
Machine Model WA1200-6

Engine SSDA16V 160E-2
Measurement Standard value
Item Unit Repair limit
condition for new machine
E 625 to 675 575 to 725
Low idle
P 625 to 675 575 to 725
a E: Econo-
E 1,850 to 1,950 1,800 to 2,000
my mode
Engine speed High idle rpm
P: Power
P 1,850 to 1,950 1,800 to 2,000
mode
E – –
Rated speed
P 1,800 –
kPa 196 154

Boost pressure 1,900 rpm
(mmHg) {1,470} {1,155}
At sudden acceleration Max. 4.5 Max. 4.5

Bosch
Exhaust gas color
index
At rated horsepower Max. 1.5 Max. 1.5
Blow-by pressure (coolant temperature operating range) kPa
– –
(15W-40 oil) At torque converter stall (mmH2O)
Min. 0.31 0.26
High idle MPa
Hydraulic {Min. 3.16} {2.62}
(15W-40 oil)
Low idle {kg/cm2} 0.14 0.137
{1.43} {1.4}
Engine oil temperature Whole speed range (inside oil pan) °C 80 to 110 Max. 120
(*)
When the
N {kg} 4,893 {498.95} 4,893 {498.95}
part is
Measure belt tension by using a belt
Fan belt tension new
tension gauge
When
adjusting N {kg} 4,893 {498.95} 4,893 {498.95}
tension
Push the midpoint between the drive
Air conditioner compressor belt pulleyand the air conditioner compres-
mm 9 to 12.5 9 to 12.5
tension sor pulley with a force of approx. 98 N
{10 kg}.
*: When a new part is installed, make sure to readjust after 24 hours operation.
WA1200-6 20-3
Standard value table for chassis
Standard value table for chassis 20-4

Category
Standard value
Item Measurement condition Unit for new Repair limit
machine
10.8 ± 1.0 10.8 ± 1.0
NoF, R
Transmission switch
{1.1 ± 0.1} {1.1 ± 0.1}

6.9 ± 1.0 6.9 ± 1.0
F, RoN q Engine stopped {0.7 ± 0.1} {0.7 ± 0.1}
Operating effort q Measure travel and operating ef- N {kg}
fort from/at center of lever knob. 6.9 ± 1.0 6.9 ± 1.0
Upshift
{0.7 ± 0.1} {0.7 ± 0.1}
6.9 ± 1.0 6.9 ± 1.0
Downshift
{0.7 ± 0.1} {0.7 ± 0.1}
HOLD o 18.6 (+5/0) 18.6 (+5/0)
RAISE {1.9 (+0.5/0)} {1.9 (+0.5/0)}
RAISE o 14.7 (+5/0) 14.7 (+5/0)
HOLD {1.6 + (+0.5/0)} {1.6 + (+0.5/0)}
HOLD o 10.8 (+5/0) 10.8 (+5/0)
LOWER {1.1 + (+0.5/0)} {1.1 + (+0.5/0)}
Lift arm
LOWER o
Operating effort
– –
HOLD
q Engine speed: At low speed
LOWER o 18.6 (+5/0) 18.6 (+5/0)
q Hydraulic oil temperature: 45 to N {kg}
FLOAT {1.9 + (+0.5/0)} {1.9 + (+0.5/0)}
Work equipment control levers
55 °C
FLOAT o 14.7 (+5/0) 14.7 (+5/0)
HOLD {1.5 + (+0.5/0)} {1.5 + (+0.5/0)}
HOLD o 11.8 (+5/0) 11.8 (+5/0)
DUMP {1.2 + (+0.5/0)} {1.2 + (+0.5/0)}
HOLD o 18.6 (+5/0) 18.6 (+5/0)
Bucket
TILT {1.9 + (+0.5/0)} {1.9 + (+0.5/0)}
TILT o 14.7 (+5/0) 14.7 (+5/0)
HOLD {1.5 + (+0.5/0)} {1.5 + (+0.5/0)}
HOLD o
37 ± 10 37 ± 10
RAISE
HOLD o
Lift arm 37 ± 10 37 ± 10
LOWER
q Engine speed: At low speed
Travel
HOLD o
q Hydraulic oil temperature: 45 to mm 45 ± 10 45 ± 10
FLOAT
55 °C
HOLD o
45 ± 10 45 ± 10
DUMP
Bucket
HOLD o
37 ± 10 37 ± 10
TILT
q Engine stopped
q Measure on lever knob (at 149 mm
Play from lever pivot point). mm Max. 8 Max. 10
Steering lever
q Hold the rotation of the steering ro-

tary valve.
q Flat, level, straight, dry, and paved 13.7 ± 5.0 23.5
Operating effort N {kg}
road {1.4 ± 0.5} {2.4}
Steering
q Engine speed: At full speed

Operating angle degree 80 ± 4 80 ± 4
q Left lock to right lock
Operating time
Low speed q Engine started 5.7 ± 0.5 5.7 ± 0.5

q Hydraulic oil temperature: 45 to
sec.
55 °C
Full speed q Left lock to right lock 4.9 ± 0.4 4.9 ± 0.4
20-4 WA1200-6

Accelerator pedal Category
Standard value
machine
60 (+10/0) 60 (+10/0)
a See figure A {6.1 (+1.0/0)} {6.1 (+1.0/0)}
NEUTRAL q Engine speed: At low speed
q Hydraulic oil temperature: 45 to 57 –
(a1)
Operating angle 55 °C degree
Max. (a2) 40 –
Right 300 (+30/0) 300 (+30/0)

Left {30.6 (+3/0)} {30.6 (+3/0)}
a See figure B
NEUTRAL a Right: Right brake Right 45 –
Brake pedal
(a1) Left: Left brake Left 53 –

Operating angle q Engine speed: At low degree
speed Right 15(+4/0) –
Max. (a2)
q Hydraulic oil tempera- Left 16.9 –
ture: 45 to 55 °C
Right
Play mm 5 ± 0.5 –
Left
A Max. 2.5 –
Fitting of wheel lock ring a See figure C
B Max. 4.0 –
Tire
q Tire inflation pressure: Specified mm

Clearance of wheel lock pressure
C 2 to 10 –
ring
a E: Economy mode E 1,750 to 1,950 1,650 to 2,000
At torque converter stall P: Power mode
q Coolant temperature: P 1,800 to 2,000 1,700 to 2,000
Within operating range
Engine speed
q Torque converter oil E 1,750 to 1,950 1,650 to 2,000

Hydraulic stall temperature: 60 to rpm
80 °C P 1,800 to 2,000 1,700 to 2,000
q Hydraulic oil tempera-
At torque converter stall ture: 45 to 55 °C E 1,600 to 1,950 1,500 to 2,000
and q Gear shift lever: F4 or
Hydraulic stall R4 P 1,650 to 2,000 1,550 to 2,000
2.5 ± 0.15 2.5 ± 0.15
Low speed
Main relief pres- q Torque converter oil temperature: {26 ± 1.5} {26 ± 1.5}
Transmission and torque converter
sure 60 to 80 °C 2.7 ± 0.15 2.7 ± 0.15

Full speed
{28 ± 1.5} {28 ± 1.5}
Torque converter relief (inlet) Max. 1.22 Max. 1.22
q Torque converter oil temperature:
pressure {Max. 13} {Max. 13}
60 to 80 °C
Torque converter outlet oil pres- 0.88 ± 0.1 0.88 ± 0.1
q Engine speed: At full speed MPa
sure 2 {9 ± 1} {9 ± 1}
q Torque converter oil temperature: {kg/cm } 2.45 ± 0.15 2.45 ± 0.15
ECMV output 1st
60 to 80 °C {25 ± 1.5} {25 ± 1.5}
(clutch) oil pres-
2nd, 3rd q Engine speed: At full speed 2.45 ± 0.15 2.45 ± 0.15
sure
MOD/C, F-R q Manual switch at ON {25 ± 1.5} {25 ± 1.5}
Lubrication (oil cooler outlet) 0.05 to 0.26 0.05 to 0.26
60 to 80 °C
pressure {0.5 to 2.7} {0.5 to 2.7}
31.36 31.36
Steering relief pressure (+0.98/-0.29) (+0.98/-1.27)
Hydraulic oil temperature: 45 to MPa
Steering
q
{320 (+10/-3)} {320 (+10/-13)}
55 °C
q Engine speed: At full speed {kg/cm2} 3.72(+0.19/0) 3.72
Orbit-roll output pressure (+0.39/-0.19)
{38 (+2/0)}
{38 (+4/-2)}
WA1200-6 20-5

Category
Standard value
machine
q Checking to
be per-
fomed when
17.6
the brake oil 17.6 (+0.59/0)
Charge cut-in pressure (+1.56/–0.98)
pressure {180 (+6/0)}
q Engine speed: At {180 (+16/–10)}
Accumulator
warning
full speed MPa
lamp goes
q Hydraulic oil tem-
perature: 45 to
off. {kg/cm2}
q Measure
55 °C
when brake
20.6
oil pressure 20.6 (+1.47/0)
Charge cut-out pressure (+1.96/–0.98)
starts lower- {210 (+15/0)}
{210 (+20/–10)}
ing after ris-
ing.
1st 6.1 ± 0.3 6.1 ± 0.3
Forward 2nd 11.1 ± 0.6 11.1 ± 0.6

Power train
3rd gear speed 18.9 ± 0.9 18.9 ± 0.9

Travel speed km/h
1st 6.3 ± 0.4 6.3 ± 0.4
Reverse 2nd 11.9 ± 0.6 11.9 ± 0.6
3rd gear speed 19.3 ± 1.0 19.3 ± 1.0

q Hydraulic oil temperature: 45 to 15.5 ± 1.4 15.5 ± 2.0
Brake oil pressure
55 °C {158 ± 14} {158 ± 20}
q Engine stopped
MPa
q Keep brake pedal depressed at
Drop of brake oil pressure {kg/cm2} Max. 1.4 {14} Max. 1.4 {14}
4.9 MPa {50 kg/cm2} and measure
drop in oil pressure after 5 min-
utes.
q Tire inflation pressure: Specified
Wheel brake
pressure
q Flat, level, straight, and dry paved
road
q Speed when applying brake: 20
Performance km/h, Delay in depressing pedal: m Max. 6 Max. 6
Max 0.1 second
q Brake pedal depressing force:
Specified operating effort 294 ±
29.4 N {30 ± 3 kg}
q Measure braking distance.
a See figure D
Wear of disc mm 0 7.0
q Measure the piston stroke.
2.65 ± 0.2 2.65 ± 0.2
Full speed
{27 ± 2} {27 ± 2}
Parking brake
At emer- q Torque converter oil temperature: MPa
inlet pressure 2.94 ± 0.29 2.94 ± 0.29
gency 60 to 80 °C
{kg/cm2} {30 ± 3} {30 ± 3}
Parking brake
release q Engine speed: At Full speed

2.65 ± 0.2 2.65 ± 0.2
Parking brake pilot pressure
{27 ± 2} {27 ± 2}
a See figure E
Performance – Stopped Stopped
q Tire inflation pressure: Specified
pressure
q Flat paved road with a slope of 1/5
Disc thickness mm 3.2 ± 0.1 2.77
(11 deg. 20') and dry surface
q Set machine in operating state.
20-6 WA1200-6
(04)

Category
Standard value
machine
q Hydraulic oil temperature: 45 to 3.72
3.72 (+0.98/0)
PPC pump pressure 55 °C (+1.47/-0.49)
{38 (+10/0)}
q Engine speed: At full speed {38 (+15/-5)}
3.72 (+0.2/0) 3.72 ± 0.2
PPC valve source pressure 55 °C
{38 (+2/0)} {38 ± 2}
Lift arm
RAISE, q Hydraulic oil temperature: 45 to MPa
PPC
EPC valve out-

FLOAT; 55 °C {kg/cm2} 3.72 (+0.2/0) 3.72 ± 0.2
Bucket q Engine speed: At full speed
put pressure {38 (+2/0)} {38 ± 2}
DUMP, TILT q Work equipment control lever with
Lift arm full operation
LOWER
q Hydraulic oil temperature: 45 to 2.94
2.94 (+0.98/0)
Control pump pressure 55 °C (+1.47/-0.49)
{30 (+10/0)}
q Engine speed: At full speed {30 (+15/-5)}
q Hydraulic oil temperature: 45 to MPa 31.36 31.36
Work equipment relief pressure 55 °C 2 (+0.98/-0.29) (+0.98/-1.27)
q Engine speed: At full speed {kg/cm } {320 (+10/-3)} {320 (+10/-3)}
RAISE 13.5 ± 0.5 13.5 ± 0.5

a See Fig. F
Lift arm speed

LOWER 55 °C 5.3 ± 0.5 5.3 ± 0.5
q With no load
Work equipment valve
FLOAT Sec. 5.0 ± 0.5 5.0 ± 0.5
a See Fig. G
Bucket speed
Tilt back
4.1 ± 0.3 4.1 ± 0.3
(At full stroke)
55 °C
DUMP q Engine speed: At full speed 2.7 to 3.3 2.7 to 3.3
(At full stroke) q With no load
a See Fig. H
Bucket hinge pin drop
q Hydraulic oil temperature: 45 to Max. 250 Max. 250
amount
Hydraulic drift
55 °C
q Stop the engine and leave it for
mm Max. 100 Max. 100
five minutes, then take measure-
(Does not (Does not
Bucket cutting edge drop ment for 15 minutes.
include bucket include bucket
amount q Apply no load to bucket and set lift
hinge pin drop hinge pin drop
arm and bucket in level position.
amount.) amount.)
WA1200-6 20-7
a Drawing related to standard value table
20-8 WA1200-6
SEN0547510-00 30-1
WA1200-6
WHEEL LOADER
Shop Manual 3-01
WA1200-6

WA1200-6 60001 and up
30 Testing and adjusting 30-1
WA1200-6 30-1
Contents
Contents 30-2
30 Testing and adjusting
Tool for testing, adjusting and troubleshooting ....................................................................... 30- 4
Tools for testing, adjusting, and troubleshooting ................................................................. 30- 4
Safety precautions to follow before starting work ................................................................ 30- 9
Testing engine speed........................................................................................................... 30- 13
Testing exhaust gas color .................................................................................................... 30- 15
Testing blow-by pressure..................................................................................................... 30- 16
Measuring engine oil pressure............................................................................................. 30- 17
Measuring exhaust gas temperature ................................................................................... 30- 18
Testing intake air pressure (boost pressure) ....................................................................... 30- 19
Testing radiator performance............................................................................................... 30- 20
Measuring wind speed across radiator and oil cooler.......................................................... 30- 21
Testing and adjusting fan belt tension ................................................................................. 30- 22
Testing and adjusting air conditioner compressor belt tension ............................................ 30- 23
Power train.............................................................................................................................. 30- 24
Adjusting speed sensor........................................................................................................ 30- 24
Testing and adjusting torque converter and transmission oil pressure................................ 30- 26
Traction control function checking procedure ...................................................................... 30- 29
Testing torque converter oil cooler performance ................................................................. 30- 30
Testing additional cooler fan speed ..................................................................................... 30- 31
Flushing procedure for torque converter and transmission circuit ....................................... 30- 32
Retrieval of disabled machine due to transmission valve failure ......................................... 30- 33
How to measure play of center hinge bearing ..................................................................... 30- 36
Measuring wear of rear axle support ................................................................................... 30- 38
Steering system ...................................................................................................................... 30- 39
Testing and adjusting steering oil pressure ......................................................................... 30- 39
Testing and adjusting emergency steering oil pressure....................................................... 30- 40
Bleeding air from steering circuit.......................................................................................... 30- 42
Testing and adjusting steering stopper bolt ......................................................................... 30- 44
Adjusting steering follow-up linkage..................................................................................... 30- 45
Testing steering EPC valve.................................................................................................. 30- 50
Testing and adjusting steering surge cut valve oil pressure ................................................ 30- 52
Testing and adjusting steering main relief valve oil pressure .............................................. 30- 54
Testing rotary valve output pressure.................................................................................... 30- 56
Brake system .......................................................................................................................... 30- 58
Testing brake performance .................................................................................................. 30- 58
Testing lowering of wheel brake oil pressure....................................................................... 30- 59
Testing of slack adjuster ...................................................................................................... 30- 60
Mesuring wear of wheel brake disc...................................................................................... 30- 61
Testing and adjusting accumulator charge pressure ........................................................... 30- 62
Testing brake accumulator oil pressure leakage ................................................................. 30- 64
Testing emergency parking brake valve oil leakage amount ............................................... 30- 66
Testing brake valve oil leakage amount............................................................................... 30- 69
Testing brake cooling oil pressure ....................................................................................... 30- 74
Testing brake oil cooler performance................................................................................... 30- 76
Testing parking brake performance ..................................................................................... 30- 76
Testing wear of parking brake disc ...................................................................................... 30- 77
Method of releasing parking brake manually ....................................................................... 30- 78
Testing parking brake oil pressure....................................................................................... 30- 79
30-2 WA1200-6
Contents
Testing accumulator nitrogen gas pressure and procedure for charging accumulator with
nitrogen gas ......................................................................................................................... 30- 80
Testing and adjusting work equipment oil pressure by using multi monitor......................... 30- 86
Testing and adjusting work equipment oil pressure by using oil pressure gauge................ 30- 88
Testing and adjusting work equipment PPC oil pressure .................................................... 30- 89
Measuring point of hydraulic pump oil pressure .................................................................. 30- 91
Testing and adjusting PV control relief valve oil pressure ................................................... 30- 95
Testing and adjusting differential valve output oil pressure ................................................. 30- 97
Testing work pump ES valve output pressure ..................................................................... 30- 99
Testing and adjusting work pump CO (cut-off) valve oil pressure ....................................... 30- 101
Testing and adjusting work equipment pump TVC valve oil pressure ................................. 30- 105
Operation test of work equipment valve by work equipment speed (speed of work
equipment is low)................................................................................................................. 30- 107
Testing hydraulic oil cooler performance ............................................................................. 30- 114
Bleeding air from hydraulic circuit........................................................................................ 30- 117
Releasing remaining pressure in hydraulic circuit ............................................................... 30- 122
Work equipment...................................................................................................................... 30- 123
Checking center hinge pin lubrication.................................................................................. 30- 123
Adjustment method of auto grease injector delivery ............................................................ 30- 125
Setting method of auto grease timer.................................................................................... 30- 126
Testing and adjusting bucket proximity switch..................................................................... 30- 128
Adjusting lift arm potentiometer ........................................................................................... 30- 129
Adjusting lift arm levelness detecting switch........................................................................ 30- 130
Initial setting procedure for remote boom positioner (origin input method).......................... 30- 131
Checking proximity switch operation pilot lamp ................................................................... 30- 132
Adjusting AJSS lever angle sensor and frame angle sensor ............................................... 30- 133
Testing and adjusting potentiometer mounting position ...................................................... 30- 134
Procedure for testing diodes................................................................................................ 30- 137
Basic precautions for KOMTRAX Plus controller................................................................. 30- 138
Inspection and maintenance of KOMTRAX Plus controller ................................................. 30- 147
Initial setting procedure for KOMTRAX Plus controller ........................................................ 30- 148
Precautions for replacing KOMTRAX Plus controller .......................................................... 30- 165
Measurement procedure by downloading data in KOMTRAX Plus controller ..................... 30- 173
Measurement procedure by multi monitor ........................................................................... 30- 177
Special functions of multi monitor ........................................................................................ 30- 179
Pm Clinic................................................................................................................................. 30- 236
Outline of measurement procedure for Pm Clinic ................................................................ 30- 236
Preparation for measurement for Pm Clinic......................................................................... 30- 237
Pm clinic service .................................................................................................................. 30- 238
WA1200-6 30-3
Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting
Tool for testing, adjusting and troubleshooting 30-4

Tools for testing, adjusting, and troubleshooting 30-4
Sym-
Testing and adjusting item Part No. Part name Remarks
bol
Coolant temperature, oil
temperature, and exhaust B 799-101-1502 Digital thermometer set -99.9 to 1,299 °C
temperature
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Analog hydraulic tester
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester Pressure gauge: 60 MPa {600 kg/cm2}
2 799-101-5160 q Nipple PT 1/8
3 790-301-1271 q Joint Male 10 x 1.25, PT 1/8
4 790-261-1311 q Adapter Male, female 14 x 1.5, PT 1/8
Hydraulic C 5 799-203-2440 Nipple Male 18 x 1.5, PT 1/8
6 799-401-2320 Hydraulic gauge 1 MPa {10 kg/cm2}
7 790-261-1331 q Adapter 22 x 1.5
8 790-261-1321 q Adapter 18 x 1.5
9 07376-50315 q Plug PPC hose side
10 07221-20315 q Sleeve nut (Central block side)
11 07222-00312 q Plug (Central block side)
1 799-201-9002 Handy smoke checker
Exhaust gas color G Commercially Bosch index: 0 to 9
2 Smoke meter
available
Commercially
Pedal depressing angle H Angle gauge
available
793-520-1805 Brake test kit –
Brake oil pressure I
793-520-1851 q Nipple –
1 79A-264-0021 0 to 294 N {0 to 30kg}
Operating effort J Push-pull scale
2 79A-264-0091 0 to 490 N {0 to 50kg}
Measuring stroke and Commercially
K Ruler
hydraulic drift available
Commercially
Work equipment speed L Stopwatch –
available
Measurement of brake disc Commercially
M Vernier calipers –
for wear available
792-415-1200 Fixed valve assembly (Note)
792-415-110 q Cover Assembly part number 792415-1200
Retrieval of disabled 1 792-415-1120 q Spacer Since this kit is for dump trucks, it also
machine due to transmis- N 175-15-15540 q Valve includes 792415-1130 (spacer: 3rd,
sion valve failure 238-15-12930 q Spring with stamping mark H) and
792-415-1150 q Wrench 792415-1140 (spacer: 4th, with stamp-
2
792-415-1160 q Adapter ing mark L).
Measuring voltage and
O 79A-264-0211 Circuit tester –
resistance
DT series connector
799-601-7600 –
adapter assembly
799-601-7610 q Adapter For DT series 2P
799-601-7660 q Adapter For DTM series 2P
Diagnosis of sensor and Contact size #20
P
harness 799-601-7710 q Contact (commonly used for DT series and
HD31 series)
Contact size #16
799-601-7720 q Contact (commonly used for DT series and
HD31 series)
Contact size #12
HD31 series)
30-4 WA1200-6
Sym-
bol
Contact size #8
HD31 series)
Contact size #4
HD31 series)
799-601-2500
or
799-601-2700
or
799-601-2800
or T-adapter assembly
799-601-7100
or
799-601-7400
or
799-601-8000
For M1C-13P (not included in
799-601-2720 q Adapter for MIC 799-601-2800, 799-601-7100,
799-601-8100)
799-601-2730 q Adapter for MIC For MIC-17P
799-601-2740 q Adapter for MIC For MIC-21P
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
Diagnosis of sensor and 799-601-7020 q Adapter for X For X-2P
P 799-601-7030 q Adapter for X For X-3P
harness
For SWP-6P (not included in
799-601-7050 q Adapter for SWP
799-601-8000)
For SWP-8P (not included in
799-601-7060 q Adapter for SWP
799-601-8000)
For M-1P (not included in
799-601-7080 q Adapter for M
799-601-7000, 799-601-7100)
799-601-7090 q Adapter for M For M-2P
799-601-7140 q Adapter for M For S-8P
799-601-7150 q Adapter for S (white) For S-10P (white)
For S-12P (blue)
799-601-7160 q Adapter for S (blue)
(not included in 799-601-8000)
For 040-12P (not included in
799-601-7190 q Adapter for 040
799-601-7000, 799-601-7100)
799-601-7210 q Adapter for 040 For 040-16P
799-601-7220 q Adapter for 040 For 040-20P
799-601-4101
or
799-601-4201
799-601-9000
or
799-601-9200
799-601-9020 q Adapter for DT For DT-2P
For DT-3P (not included in
799-601-9030 q Adapter for DT
799-601-4101, 799-601-4201)
799-601-9040 q Adapter for DT For DT-4P
799-601-9050 q Adapter for DT
799-601-4101, 799-601-4201)
WA1200-6 30-5
Sym-
bol
799-601-9060 q Adapter for DT (gray)
799-601-4101, 799-601-4201)
For DT-8P (black) (not included in
799-601-9070 q Adapter for DT (black)
799-601-4101, 799-601-4201)
For DT-12P (gray) (not included in
799-601-9110 q Adapter for DT (gray)
799-601-4101, 799-601-4201)
799-601-7400 T-adapter assembly
Diagnosis of sensor and 799-601-7180 q Adapter for 040 For 040-8P
P
harness 799-601-7500 T-adapter assembly
799-601-7510 q Adapter for APM070 For APM070-10P
Out of kit (not included in kit)
799-601-7310 Adapter for SWP For SWP-12P
Flushing procedure for
Element Standard element installed
torque converter and trans- – 07063-41210
(for flushing) 07063-01210
mission hydraulic circuit
KOMTRAX Plus analysis
1 799-608-3211
tool
Initial setting and setting 2 799-608-3220 Wiring harness
after replacement of Q Commercially
3 Note type PC (OS: Windows 98/2000)
KOMTRAX Plus controller available
21T-06-64590 Coupling assembly
4 Pm clinic
21T-06-64392 Wiring harness
792-610-1701 Gas charge tool kit
792-610-1700 q Gas charge tool For old type accumulators
07000-11009 q O-ring
1 792-610-1702 Gas charge tool kit
792-610-1700 q Gas charge tool
For old and new type accumulators
07000-11009 q O-ring
792-610-2310 q Extension
Filling gas into accumulator R 792-610-1310 Nipple (For Russia) GOST
792-610-1320 Nipple (For USA) CGA No.351
792-610-1330 Nipple (For USA) ASA B-571-1965
DIN 477-1963
2
792-610-1350 Nipple (For Germany) NEN3268-1966
SIS-SMS 2235/2238
BS 341
792-610-1360 Nipple (For UK)
Part1-1962
Commercially
Measuring wind speed S Anemometer
available
Measuring fan speed T 799-205-1100 Tachometer kit Digital display: 6.0 to 99,999 rpm
30-6 WA1200-6
Sym-
Q'ty
bol
799-601-4101
or T-adapter assembly 1
799-601-4201
For DRC60, ECONO
799-601-4350 q T-box 1 (does not include in Kit No.
799-601-4201)
For engine (CRI-T3) water temperature
sensor (PACKARD 2P)
For engine (CRI-T3) fuel temperature
795-799-5530 q Socket 1
sensor (PACKARD 2P)
For engine (CRI-T3) oil temperature
sensor (PACKARD 2P)
For engine (CRI-T3) ambient pressure
799-601-4140 q Socket 1
sensor (AMP 3P)
For engine (CRI-T3) boost pressure
799-601-4230 q Socket 1 sensor and boost temperature sensor
(SUMITOMO 4P)
Troubleshooting for For engine (CRI-T3) G (backup) sensor
799-601-4330 q Socket 1
engine, (SUMITOMO 3P)
–
controller sensor, For engine (CRI-T3) supply pump PCV
799-601-4340 q Socket 1
and actuator 1 and PCV 2 sensors (SUMITOMO 3P)
For engine (CRI-T3) NE sensor
799-601-4130 q T-adapter 1
(FRAMATOME 3P)
For engine (CRI-T3) common rail fuel
799-601-4190 q T-adapter 1
pressure sensor (AMP 3P)
For engine controller DRC26-50P
799-601-4211 q T-adapter 1 (does not include in Kit No.
799-601-4201)
For engine controller DRC26-60P
799-601-4201)
For engine controller DTP-4P
799-601-4260 q Adapter for DTP 1 (Included in Kit Nos. 799-601-9000 and
799-601-9100, too)
For DT 4P (Included in Kit Nos.
799-601-9040 q T-adapter 1
799-601-9000 and 799-601-9200, too)
For DT 2P (Included in Kit Nos.
799-601-9020 q T-adapter 1
799-601-9000 and 799-601-9200, too)
799-601-9000
or
or
799-601-9300
799-601-9320 q T-box 1 For ECONO (Max. 24P)
799-601-4101 q T-adapter assembly
799-601-4350 q T-box 1 For DRC60, ECONO (Max. 60P)
799-601-7000
Troubleshooting for or
machine – 799-601-7100
wiring harness or T-adapter assembly
799-601-7400
or
799-601-8000
For ECONO (Max. 21P)
799-601-2600 q T-box 1 (does not include in Kit No.
799-601-7000)
799-601-7210 q T-adapter 1 For AMP040 16P
799-601-7090 q T-adapter 1 For M 2P
WA1200-6 30-7
Sym-
Q'ty
bol
799-601-7340 q T-adapter 1 For M 8P (Kit No. is not registered)
799-601-7140 q T-adapter 1 For S 8P
For S 12P (white) (Kit No. is not regis-
799-601-7350 q T-adapter 1
tered)
799-601-7170 q T-adapter 1 For S 16P (blue)
For S 16P (white) (Kit No. is not regis-
799-601-7330 q T-adapter 1
tered)
For SWP 8P
799-601-8000)
For SWP 12P
799-601-8000)
For SWP 14P
799-601-8000)
799-601-7320 q T-adapter 1 For SWP 16P (Kit No. is not registered)
799-601-7010 q T-adapter 1 For X 1P
Troubleshooting for
machine –
799-601-9000
wiring harness
799-601-9200
For DT 4P (included in Kit Nos.
799-601-9040 q T-adapter 1
799-601-4101 and 799-601-4201, too)
799-601-9020 q T-adapter 1 For DT 2P
799-601-9110 q T-adapter 1 For DT 12P (gray)
799-601-9120 q T-adapter 1 For DT 12P (black)
799-601-9130 q T-adapter 1 For DT 12P (green)
799-601-9140 q T-adapter 1 For DT 12P (brown)
For HD36 24-21P
(does not include in Kit No.
799-601-9270 q T-adapter 1
799-601-9200)
(included in Kit No. 799-601-9100, too)
799-601-9360 q T-adapter 1 For pump controller DRC26-24P
799-601-9350 q T-adapter 1 For pump controller DRC26-40P
799-601-7360 T-adapter 1 For 5P-relay (Kit No. is not registered)
799-601-7370 T-adapter 1 For 6P-relay (Kit No. is not registered)
For AMP 3P (pressure sensor)
799-601-9420 T-adapter 1 (included in Kit No. 799-601-4101 and
799-601-4201, too)
30-8 WA1200-6
Safety precautions to follow before starting work
Safety precautions to follow before starting work 30-9

1. Perform repair and maintenance with the 4) Move parking brake switch (3) to the "ON
machine placed on a stiff and flat ground. (Parking)" position.
1) Wash the machine.
a Thoroughly wash the portions to be re-
moved.
5) Move the frame lock lever to the "Lock (L)"

position.
2) Move the machine to the workshop and lower

the work equipment to the ground.
a If performing work outdoors, park the ma-
chine on a stiff and flat surface and lower
the work equipment to the ground.
6) Stop the engine.
3) Move the gear shift switch to the "N" position.
WA1200-6 30-9
7) Place blocks under the wheels. 3) Move joystick lever (lock lever) (1) to the
"LOCK" position.
2. Release the remaining pressure in the

hydraulic circuit. 4) Loosen hydraulic tank cap (4).
1) Operate the work equipment control levers (Hold the cap at a position where a hissing
(lift arm and bucket) back and forth slowly sound is heard.)
two or three times in full strokes.
a Hydraulic sound will cease when there is
no more pressure remaining in the circuit.
5) Depress the brake pedal ten times in full

strokes. (Until no hydraulic sound is heard.)
2) Move work equipment lock lever (1) to the
"LOCK" position.
30-10 WA1200-6
6) Loosen brake tank filler cap (3). k If refrigerant gas gets in your eyes, you
(Hold the cap at a position where a hissing may lose your sight. And if it touches your
sound is heard.) skins, you may suffer from frostbite. Ac-
cordingly, put on the protective eyeglass-
es, gloves and working suits with long
sleeves while you are collecting or filling
the refrigerant (R134a).
Refrigerant to be collected: 1.3 to 1.5 kg
4. Disconnect the electricity from the battery.

(Machines equipped with a battery disconnect
switch)
Turn the battery disconnect switch in the battery
box to the "OFF" position.
7) Attach a DO NOT OPERATE tag to lever (1).
(Machines not equipped with a battery discon-

nect switch)
Disconnect the cable from the negative (-)
terminal of the battery.
3. Handling air conditioner refrigerant
k If hoses and tubes of the air conditioner
circuit are going to be disconnected, col-
lect the refrigerant (R134a) from the air
conditioner circuit.
a Ask a qualified person for collecting, adding
and filling operations of the refrigerant
(R134a).
a Never release the refrigerant (R134a) to the
atmosphere. It is the subject of penalty by the
"Law Concerning Collection and Decomposi-
tion of Freon."
WA1200-6 30-11
5. Getting on and off the machine

Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine.
When a scaffolding is not provided, use steps or
a step ladder to secure your footing.
30-12 WA1200-6
Testing engine speed

Testing engine speed 30-13
k Be sure to follow "Safety precautions to fol- Press the "F1" switch to return to the standard
low before starting work". screen.
k When measuring, confirm that there are no Press the "F6" switch to open the screen for the
persons around the machine. highlighted menu item. (For details, see specifi-
a Measure the engine speed under the following cations for the corresponding screen.)
conditions.
q Coolant temperature: Within operating range 3. Display item "ENGINE SPEED" (page 1/4 of
q Hydraulic oil temperature: 45 to 55 °C PM-CLINIC MENU).
q Power train oil temperature: 70 to 90 °C
Measuring low idle and high idle speeds 30-13

1. Select "SERVICE MENU SELECT" on the multi
monitor screen.
2. Use item selection switches F3 and F4 to select
"Pm Clinic", and then press F6 switch to display
the "Pm Clinic" screen.
Press the "F1" switch to return to the Service

Menu screen.
Press the "F2" switch to move to the previous
page.
When pressed in page 1, the screen changes to
page 4.
Press the "F5" switch to move to the next page.
When pressed in page 4, the screen changes to
page 1.
When the "F3" switch is pressed when the value
is not held, the value is held.
(The button changes to "Unhold")
When the "F3" switch is pressed when the value
is held, the held value is released.
(The button changes to "Hold")
4. Start the engine and measure the engine speed

at low idle and high idle.
5. If [F3] switch is pressed when reading the engine

speed, the engine speed value is held.
a If the hold [F3] switch is pressed again, the
When changed to this screen (SERVICE MENU
value is released.
SELECT) the real-time monitor is high lighted.
Press the "F3" switch to move the highlight to the
next (lower) menu item. (Scroll function)
When the "F3" switch is pressed at the bottom
item, the highlight moves to the top item.
Pressing "F4" switch moves the highlight to the
upper menu item. (Scroll function)
When the "F3" switch is pressed at the top item,
the highlight moves to the bottom item.
WA1200-6 30-13
Testing engine speed
Measuring torque converter stall speed 30-14 Measuring torque converter + hydraulic stall
1. Set transmission cut-off switch (1) to OFF and speed 30-14
depress left brake (4) securely (to switch the 1. In the same way as "Measuring low idle and high
transmission cut-off). idle speeds", display item "Engine speed" on the
2. Set transmission auto/manual shift selector real-time monitor screen.
switch (3) to "ON (Manual)". 2. Set transmission cut-off switch (1) to OFF and
a At this time, the gear shift mode is in "2nd". depress left brake (4) securely (make sure that
3. Press upshift switch (7) to upshift to "3rd". the transmission cut-off pilot lamp is off).
(Note) In 2nd the machine will move because 3. Set transmission auto/manual shift selector
drive force is larger than braking force. switch (3) to "ON (Manual)".
Therefore, use 3rd in which the braking force a At this time, the gear shift mode is in "2nd".
becomes larger than the drive force. 4. Press the upshift switch to upshift to "3rd".
4. Set forward and reverse (FNR) switch (6), in "F" (Note) In 2nd the machine will move because
or "R". drive force is larger than braking force.
5. Set parking brake switch (5) to the OFF position Therefore, use 3rd in which the braking force
to release the brake. becomes larger than the drive force.
6. Measure the engine speed when the torque 5. Set forward and reverse (FNR) switch (6), in "F"
converter is in the stalled condition with the or "R".
engine at full speed. 6. Set parking brake switch (5) to the OFF position
to release the brake.
7. Relieve the lift arm cylinder or bucket cylinder on
the extraction side with engine at full throttle and
torque converter stalled, and then measure the
engine speed.
a Engine speed standard values
Engine mode fixed to AUTO or P mode
(rpm)
Standard value
Testing condition for new Repair limit
machine
Low idle 625 to 675 575 to 725
High idle 1,850 to 1,950 1,800 to 2,000
Torque converter stall 1,800 to 2,000 1,700 to 2,000
Hydraulic stall 1,800 to 2,000 1,700 to 2,000
Full stall 1,650 to 2,000 1,550 to 2,000
Measuring hydraulic stall speed 30-14
1. Relieve the lift arm cylinder or bucket cylinder on Engine mode fixed to E mode
the extraction side with engine at full throttle, and (rpm)
measure the engine speed. Measurement condi-
Standard value
for new Repair limit
tion
machine
Low idle 625 to 675 575 to 725
High idle 1,850 to 1,950 1,800 to 2,000
Torque converter stall 1,750 to 1,950 1,650 to 2,000
Hydraulic stall 1,750 to 1,950 1,650 to 2,000
Full stall 1,600 to 1,950 1,500 to 2,000
30-14 WA1200-6
Testing exhaust gas color
Testing exhaust gas color 30-15

a Testing tools
Symbol Part No. Part name
1 799-201-9002 Handy smoke checker
G Commercially
2 Smoke meter
available
k Be sure to follow "Safety precautions to fol-
low before starting work".
q If an air source and an electric power source are
not available in the field, use handy smoke
checker G1. When recording official data, use
smoke meter G2.
a Raise coolant temperature to operating range,
then measure.
k When installing and removing the measuring
tools, take care not to touch a hot part of the 2) Connect the probe hose, receptacle of the
engine. accelerator switch, and air hose to tool G2.
a Limit the supplied air pressure to 1.5 MPa
1. Testing by using handy smoke checker G1 {15 kg/cm2} or below.
1) Stick a sheet of filter paper to tool G1.
2) Insert the exhaust gas inlet pipe into the
exhaust pipe and accelerate the engine
suddenly. Operate the handle of tool G1
simultaneously to let the exhaust gas be
adsorbed on the filter paper.
3) Remove the filter paper and compare it with
the attached scale.
3) Connect the power cable to an AC100V

receptacle.
a Before connecting the power cable, make
sure that the power switch of tool G2 is
turned off.
4) Loosen the cap nut of the suction pump and
fit the filter paper.
2. Testing with smoke meter G2 a Fit the filter paper securely so that the ex-
1) Insert the probe of smoke meter G2 into the haust gas will not leak.
outlet of the exhaust pipe and fix it to the 5) Turn on the power switch of tool G2.
exhaust pipe by tightening the clip. 6) Accelerate the engine suddenly and depress
the accelerator pedal of smoke meter G2
simultaneously to collect the exhaust gas on
the filter paper.
7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
WA1200-6 30-15
Testing blow-by pressure
Testing blow-by pressure 30-16

k Be sure to follow "Safety precautions to fol- 4. Test the blow-by pressure when the engine is at
low before starting work". full speed and the torque converter is stalled.
a Raise coolant temperature to operating range, k When taking measurements, take care not
then perform the test. to touch hot parts or rotating parts.
q Check on the Pm Clinic menu screen (1/4). a The blow-by pressure may vary largely with
the engine condition. If the measured value is
1. Select "SERVICE MENU SELECT" on the multi judged unusual, make a check for increase of
monitor screen. oil consumption, bad exhaust gas color, early
deterioration or contamination of oil, etc.
2. Use item selection switches F3 and F4 to select which are related to the unusual blow-by
Pm Clinic, and then press F6 switch to display pressure.
the "PM-CLINIC MENU" screen.
5. If [F3] switch is pressed when reading the
blow-by pressure, the value is held.
value is released.
a Blow-by pressure standard values
kPa (mmH2O)
Standard value
Conditions Repair limit
for new machine
When engine at full
speed and torque Max. 1.25 (127) Max. 3.29 (330)
converter stalling
3. Display item "Blowby pressure" (page 2/4 of

"PM-CLINIC MENU" screen).
30-16 WA1200-6
Measuring engine oil pressure
Measuring engine oil pressure 30-17

k Be sure to follow "Safety precautions to fol- 5. If [F3] switch is pressed when reading the engine
low before starting work". oil pressure, the value is held.
a Raise coolant temperature to operating range, a If the hold [F3] switch is pressed again, the
then measure. value is released.
q Check on the Pm Clinic menu screen (1/4).
a Engine oil pressure standard values
1. Select "SERVICE MENU SELECT" on the multi q 15W to 40 oil
monitor screen. q Coolant temperature: Within operating range
(MPa {kg/cm2})
2. Use item selection switches F3 and F4 to select Standard value
Pm Clinic, and then press F6 switch to display Conditions for new Repair limit
the "PM-CLINIC MENU" screen. machine
Min. 0.31 {Min. 0.26
High idle
{3.16}} {2.62}
0.113
Low idle 0.14 {1.43}
{1.15}
3. Display item "Engine oil pressure" (page 1/4 of

4. Start the engine and measure the engine oil

pressure while running the engine at high idle.
k When taking measurements, take care not
to touch hot parts or rotating parts.
WA1200-6 30-17
Measuring exhaust gas temperature
Measuring exhaust gas temperature 30-18

k Be sure to follow "Safety precautions to fol- Measurement procedure 30-18
low before starting work". 1. When measuring the maximum value in trouble-
a Raise coolant temperature to operating range, shooting
then measure. Operate the machine actually and measure the
q Check on the Pm Clinic menu screen (1/4). maximum value.
(Note) The exhaust gas temperature largely
1. Select "SERVICE MENU SELECT" on the multi depends on the outside air temperature (intake
monitor screen. air temperature of the engine). Accordingly, if
any abnormal value is obtained, correct it.
2. Use item selection switches F3 and F4 to select a Corrected value = Measured value + 2 x
Pm Clinic, and then press F6 switch to display (Conversion ambient temperature - Ambient
the "PM-CLINIC MENU" screen. temperature)
a Conversion ambient temperature is assumed
to be 20 °C.
2. Procedure for measuring periodically for preven-

tive service
1) Raise the exhaust temperature in a full stall
condition (torque converter stalled+ work
equipment pump relieved).
(Approx. 700 °C ... standard value)
2) From the above condition, quit hydraulic
pressure relief and put the machine in only
the torque converter stalled condition. (The
temperature starts to decrease. If the
temperature does not go down but rises,
make the set temperature at step (1) in the
3. Display item "Exhaust gas temperature" (page
following drawing higher.)
2/4 of "PM-CLINIC MENU" screen).
3) Measure the temperature when it starts to

4. If [F3] switch is pressed when reading the
decrease and then stabilizes.
exhaust gas temperature, the value is held.
a If only the torque converter is put in the
stalled condition, the torque converter will
value is released.
overheat before the exhaust temperature
stabilizes.
30-18 WA1200-6
Testing intake air pressure (boost pressure)
Testing intake air pressure (boost pressure) 30-19

k Be sure to follow "Safety precautions to fol- 5. If [F3] switch is pressed when reading the boost
low before starting work". pressure, the value is held.
a Raise coolant temperature to operating range, a If the hold [F3] switch is pressed again, the
then measure. value is released.
q Check on the Pm Clinic menu screen (1/4).
a Boost pressure standard values
1. Select "SERVICE MENU SELECT" on the multi (kPa {mmHg})
monitor screen. Standard value
Conditions for new Repair limit
2. Use item selection switches F3 and F4 to select machine
Pm Clinic, and then press F6 switch to display 196 ± 15 154
1,900 rpm
{1,470 ± 113} {1,155}
3. Display item "Boost pressure" (page 2/4 of

4. Test the boost pressure when the engine is at full

speed and the torque converter is stalled.
a Normally, the intake air pressure (boost pres-
sure) should be tested while the engine is
running at the rated output. In the field, how-
ever, an approximate value can be obtained
by stalling the torque converter.
WA1200-6 30-19
Testing radiator performance
Testing radiator performance 30-20

Testing condition 30-20

Engine speed: High idle
Coolant temperature: Within operating range
Hydraulic oil temperature: 60 °C
a To test the radiator performance, measure the
temperature of inlet and outlet tubes with a tem-
perature gun and calculate the difference.
q Aim a temperature gun to inlet tube (1) and outlet

tube (3) to measure the temperature and calcu-
late the difference.
a Temperature difference standard value: 6 to
8 °C
30-20 WA1200-6
Measuring wind speed across radiator and oil cooler
Measuring wind speed across radiator and oil cooler 30-21

a Testing tools 2. Divide the rear area of the hydraulic oil cooler
Symbol Part No. Part name into eight rows (1 to 8) and eight columns (A to
H) to decide the positions to measure the wind
S Commercially available Anemometer speed.
a When the engine is running, measure the wind
speed (wind force) at the rear of the hydraulic oil
cooler by using tool S anemometer to check if
the wind speed is within the standard value
range.
Average wind speed standard value: Min. 15 m/s
3. Run the engine at 1,900 rpm (rated speed) and

measure the wind speed at the 8 x 8 positions
(A:1 to H:8) divided in step 2. Note the measured
values in the table.
A B C D E F G H
1st
2nd
3rd
4th
Testing procedure 30-21 5th
1. Open radiator grille (1). 6th
7th
8th
4. Calculate the mean value of the values entered

in step 3, and check if it is within the standard
range.
(A:1) + (B:1)... (G:8) + (H:8)/64=Mean value
a Average wind speed standard value: Min. 15
m/s
5. If the wind speed is below the standard value,

the hydraulic oil cooler is clogged or the cushion
is damaged. Perform cleaning and checking.
WA1200-6 30-21
Testing and adjusting fan belt tension
Testing and adjusting fan belt tension 30-2

k Be sure to follow "Safety precautions to fol- Adjusting 30-2
low before starting work". 1. Loosen bolt (2) and adjust the tension with bolt
(3).
Checking 30-2 a When bolt (3) is turned clockwise, the tension
1. Remove fan covers (A) and (B). is increased.
2. Tighten bolt (2).
2. Check for abnormalities in fan belt (1) such as

cracks, wear, and tears.
3. Measure the tension of the fan belt (1) by using

a belt tension gauge at the midpoint between the
pulleys (e).
a Belt tension standard value: 4,893 N {498.95
kg}
30-22 WA1200-6
Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air conditioner compressor belt tension 30-23

Checking 30-23
q Press the belt at the midpoint between drive pul-
ley (1) and air conditioner compressor pulley (2)
with a force of approx. 98 N {10 kg}, and mea-
sure the belt deflection b.
a Deflection of belt (standard value) b: 9 to
12.5 mm
Adjusting 30-23
1. Loosen mounting bolt, nuts (3), (4), and (5), and
lock nut (6).
2. Loosen lock nut (8) of adjustment bolt (7) and
adjust air conditioner compressor belt (9)
tension by turning adjustment bolt (7).
3. When the position of the air conditioner
compressor is determined, tighten lock nut (8),
mounting bolt, and nuts (3), (4), (5), and (6) to
secure it in position.
4. After adjusting the belt tension, check that the
tension is within the standard value range.
WA1200-6 30-23
Power train
Adjusting speed sensor
Power train 30-24

Adjusting speed sensor 30-24
k Be sure to follow "Safety precautions to fol- Transmission output shaft speed sensor 30-24
low before starting work". 1. Screw in transmission output shaft speed sensor
(4) until its tip touches gear (5), and then back it
Engine speed sensor 30-24 off by 1/2 to 1 turn.
1. Screw in speed sensor (1) until its tip touches 2 Threaded portion: Liquid gasket
gear (2), and then back it off by 1/2 to 1 turn. (LG-5)
2 Threaded portion: Liquid gasket
(LG-5) 2. Tighten lock nut (6).
3 Locknut:
2. Tighten lock nut (3). 49.0 to 68.6 Nm {5.0 to 7.0 kgm}
3 Locknut:
49.0 to 68.6 Nm {5.0 to 7.0 kgm}
a Take extreme care not to apply an excessive
force to the speed sensor wiring when ar-
ranging the wiring.
a Take care not to let iron particles stick to the
speed sensor tip or damage it.
Modulation clutch outlet speed sensor 30-24

1. Screw in modulation clutch outlet speed sensor
(7) until its tip touches gear (8), and then back it
off by 1/2 to 3/4 turn.
2 Threaded portion: Liquid gasket
(LG-5)
2. Tighten locknut (9).

3 Locknut:
49.0 to 68.6 Nm {5.0 to 7.0kgm}
30-24 WA1200-6
Power train
Adjusting speed sensor
WA1200-6 30-25
Power train
Testing and adjusting torque converter and transmission oil pressure
Testing and adjusting torque converter and transmission oil pressure 30-26
k Be sure to follow "Safety precautions to fol- 2. Modulating pressure
low before starting work". 1) Select "SERVICE MENU SELECT" on the
multi monitor screen.
Testing 30-26 2) Use item selection switches F3 and F4 to
q Engine coolant temperature: Within operating select Pm Clinic, and then press F6 switch to
range display the "PM-CLINIC MENU" screen.
q Torque converter oil temperature: 60 to 80 °C 3) Display item "T/M MOD (transmission modu-
k Chock the wheels to prevent the machine lating) pressure (B)" (page 3/4 of
from moving. "PM-CLINIC MENU" screen).
1. Main relief pressure
1) Select "SERVICE MENU SELECT" on the
multi monitor screen.
2) Use item selection switches F3 and F4 to
select Pm Clinic, and then press F6 switch to
display the "PM-CLINIC MENU" screen.
4) Turn the drive force control dial (2) and the

travel speed control dial (3) fully clockwise.
5) With the forward and reverse switch on the
joystick steering lever in "NEUTRAL" position
and the engine running at high idle, measure
the oil pressure.
3) Display item "T/M (transmission) main pres-
sure (A)" (page 3/4 of "PM-CLINIC MENU"
screen).
a Modulating pressure standard value

Measuring point Standard value
F, R 2.3 to 2.6 MPa {23.5 to 26.5 kg/cm2}
4) Start the engine and measure the oil pres- 1st 2.1 to 2.4 MPa {21.5 to 24.5 kg/cm2}
sure while running it at high idle. 2nd 2.3 to 2.6 MPa {23.5 to 26.5 kg/cm2}
3rd gear speed 2.3 to 2.6 MPa {23.5 to 26.5 kg/cm2}
a Main relief pressure standard value
Conditions Standard value
Torque converter oil temperature: 2.45 to 2.85 MPa
60 to 80 °C {25 to 29 kg/cm2}
30-26 WA1200-6
Power train
3. Torque converter inlet oil pressure 4) Start the engine and measure the oil pres-
1) Select "SERVICE MENU SELECT" on the sure while running it at high idle.
multi monitor screen. a Torque converter outlet pressure standard
2) Use item selection switches F3 and F4 to value
select Pm Clinic, and then press F6 switch to Conditions Standard value
display the "PM-CLINIC MENU" screen. Torque converter oil temperature: 0.78 to 0.98 MPa
3) Display item "T/C (torque converter) inlet 60 to 80 °C {8 to 10 kg/cm2}
pressure (C)" (page 3/4 of "PM-CLINIC
MENU" screen).
5. Lubrication valve pressure
1) Select "Service Menu" on the multi monitor
screen.
3) Display item "T/M (transmission) lubrication
pressure (E)" (page 3/4 of "PM-CLINIC
MENU" screen).
4) Start the engine and measure the oil pres-

sure while running it at high idle.
a Torque converter inlet pressure standard val-
ue
Torque converter oil temperature: 1.08 to 1.28 MPa
60 to 80 °C {11 to 13 kg/cm2}
4. Torque converter outlet oil pressure 4) Start the engine and measure the oil pres-
1) Select "SERVICE MENU SELECT" on the sure while running it at high idle.
multi monitor screen. a Lubrication valve pressure standard val-
2) Use item selection switches F3 and F4 to ue
select Pm Clinic, and then press F6 switch to Conditions Standard value
display the "PM-CLINIC MENU" screen. Torque converter oil temperature: 0.05 to 0.15 MPa
3) Display item "T/C (torque converter) outlet 60 to 80 °C {0.5 to 1.5 kg/cm2}
pressure (D)" (page 3/4 of "PM-CLINIC
MENU" screen).
6. If [F3] switch is pressed while reading the oil
pressure, the value is held.
value is released.
7. ECMV clutch oil pressure

1) Remove the oil pressure pickup plug for the
clutch being measured.
q 1st clutch oil pressure pickup plug: (1)
q 2nd clutch oil pressure pickup plug: (2)
q 3rd clutch oil pressure pickup plug: (3)
q Reverse clutch oil pressure pickup plug:
(4)
q Forward clutch oil pressure pickup plug:
(5)
2) Install pressure gauge C1 [6 MPa
{60 kg/cm2}].
WA1200-6 30-27
Power train
3) Start the engine and measure the oil pres- Adjusting 30-28
sure for the 1st, 2nd, and 3rd clutches under k When adjusting the oil pressure, stop the en-
the following conditions. gine.
1] Keep the FNR (forward-reverse) switch in a Do not perform any adjustment if the main relief
"N" (NEUTRAL) position. pressure cannot be measured accurately.
2] Set the auto shift / manual selector switch a If the main relief pressure is out of the standard
to "ON" (manual). value, adjust according to the following proce-
3] Using the upshift and downshift switches, dure.
select each gear speed.
4] Measure with the engine running at full 1. Adjustment of transmission main relief pressure
speed. 1) To adjust oil pressure, remove the cover (1)
4) Start the engine and measure the oil pres- and increase or decrease the number of
sure for the forward and reverse clutches shims (2).
under the following conditions. a Loosen the bolts on the cover (1) gradual-
1] Set the transmission cut-off switch to ly while releasing the springs (3) and (4).
"OFF" (extinguish) position. a Standard thickness of shims: 2.0 mm
2] Turn parking brake switch OFF. a Amount of adjustment per shim (t=0.5
3] Depress brake pedal. mm):
4] Set the auto shift / manual selector switch 42.17 kPa {0.43 kg/cm2}
to "ON" (manual) position, and then a The relief pressure will increase by add-
select the "3rd" gear using the upshift ing shims, and decrease by reducing
switch. shims.
5] With the brake pedal depressed, set the q Shim part No.: 42C-13-16220
FNR (forward-reverse) switch to "F"
(forward) or "N" (reverse) position.
6] Measure with the engine running at full
speed.
a Gradually increase the engine speed
to full speed.
a ECMV clutch oil pressure standard values
q Torque converter oil temperature: 60 to
80 °C
Measuring point Standard value
2.10 to 2.40 MPa
1st
{21.5 to 24.5 kg/cm2}
2.30 to 2.60 MPa
F, R, 2nd, 3rd
{23.5 to 26.5 kg/cm2}
30-28 WA1200-6
Power train
Traction control function checking procedure
Traction control function checking procedure 30-29

1. Regarding the traction control function, put the 2. Under the following condition, the display is
multi monitor into "Real-time monitor" mode and normal if the reading is 100% when the drive
check on the "Traction setting input values" force control dial of MOD/C set at "MAX", and 0
screen to 40% when set at "MIN".
1) Select "SERVICE MENU SELECT" on the Conditions
multi monitor screen. 1) Engine low idle (engine speed: 650 rpm)
2) Use item selection switches F3 and F4 to 2) F1 shift
select Real-time monitor, and then press F6 3) Depress the right brake pedal.
switch to display the "T/M Controller" screen. 4) Set transmission cut-off switch to ON posi-
3) Display item "Traction setting input values" tion.
(page 6/12 of T/M Controller screen). 5) Release the parking brake.
a At this time, make sure that the machine
speed control switch is "OFF", and the
MOD/C emergency switch (at rear of driv-
er's seat, inside fuse box) is "OFF".
WA1200-6 30-29
Power train
Testing torque converter oil cooler performance
Testing torque converter oil cooler performance 30-30

a Testing tools 2. Performance check
Sym- 1) Start the engine and perform testing.
Part No. Part name
bol a Measure the followings with the engine at
B 799-101-1502 Digital thermometer kit full speed and the torque converter in the
Oil pressure gauge kit (ana- stalled condition.
log) a Inlet pressure: 0.3 to 0.5 MPa {3 to
799-101-5002 (Pressure gauge:
1 5 kg/cm2}
C 2.5 MPa {25 kg/cm2})
Oil pressure gauge kit (digi- Outlet pressure: 0.15 to 0.25 MPa {1.5 to
790-261-1204
tal) 2.5 kg/cm2}
2 799-101-5160 q Nipple a Oil temperature difference: 11 to 13 °C
k Be sure to follow "Safety precautions to fol- 2) When completing all measurements, stop the
low before starting work". engine and install plugs (5).

q Engine speed: Full speed
q Torque converter oil temperature: 60 °C
a To test the torque converter oil cooler perfor-
mance, measure the oil pressure at inlet and out-
let sides and the difference in temperature.
1. Install oil pressure gauge or oil temperature

gauge
q Remove plugs (5) from hose blocks (9) and
(10) and install oil pressure gauges or oil
temperature gauges to two places.
30-30 WA1200-6
Power train
Testing additional cooler fan speed
Testing additional cooler fan speed 30-31

a Testing tools 3. Run the engine at high idle and measure the fan
Sym speed.
Part No. Part name
bol
Hydraulic tester (analog) Standard value (rpm)
799-101-5002
1 40 MPa {400 kg/cm2} Specifications P mode fixed E mode fixed
C Hydraulic tester
790-261-1204 Engine speed 1,850 to 1,950 1,850 to 1,950
(digital)
7 790-261-1331 Adapter (M22) Fan speed 2,000 ± 100
T 799-205-1100 Tachometer kit
Testing conditions 30-31

q Hydraulic oil temperature: 45 to 55 °C
1. Stick reflection tape (2) of tachometer kit T to fan

(1) of the additional cooler.
2. Set probe [3] with stand [2], matching it to reflec-

tion tape (2), and connect it to tachometer [4].
WA1200-6 30-31
Power train
Flushing procedure for torque converter and transmission circuit
Flushing procedure for torque converter and transmission circuit 30-32

a Dust such as metal powder in the hydraulic cir- 5. Replace the filter elements for flushing.
cuits of the torque converter and transmission 1) Replace the elements used for flushing with
shortens the life of the torque converter and standard elements following the same proce-
transmission and causes internal breakage. To dure as in step 2-1).
remove dust in the hydraulic circuit, perform k Be sure to replace with standard ele-
flushing. ments because the filter elements
used for flushing causes premature
1. Flush the hydraulic circuit in the following cases. clogging if used for a prolonged time.
1) When metal powder flows into the circuit 2) Add the oil and check the oil level again.
because of damage to the torque converter,
transmission and hydraulic components. 6. Replace the transmission last chance oil filter.
2) When the torque converter and transmission 1) Remove case (1) of the last chance filter by
are overhauled or modified. turning portion A using a wrench.
a If there is dust in the filter case, clean it.
2. Install the element for flushing. 2) Remove element (2) and replace it with a
1) Drain the oil from the filter. new element.
2) Remove the two transmission oil filters and 3) Install a new O-ring (3) to the periphery of the
install two elements for flushing. case.
a Install the removed parts after cleaning a Apply a thin film of grease on the periph-
them and the inside of the case. ery of the O-ring.
4) Install the case.
3. Add oil to the transmission case. 3 Case mounting bolt:
q Add new oil through the oil filler port to the 58.8 to 73.55 Nm {6 to 7.5 kgm}
specified level. Run the engine to circulate
the oil through the system. Then, check the
oil level again.
5 Transmission case
approx. 350 l
4. Flush the hydraulic circuit according to the

following procedure.
1) Start the engine and run it at low speed
without operating the gear shift lever and
directional lever for approximately 20
minutes.
a Increase the engine speed up to approxi-
mately 1,500 rpm from time to time.
a If the engine coolant temperature gauge
does not rise to the green range because
of low ambient temperature, continue the
warm-up operation further.
2) Operate or travel for at least 20 minutes.
a Use all the gear speeds (forward, re-
verse, and 1st to 3rd).
3) Run the engine at low speed for about 20
minutes in the similar way as described in
4-1).
30-32 WA1200-6
Power train
Retrieval of disabled machine due to transmission valve failure
Retrieval of disabled machine due to transmission valve failure 30-3

a Testing tools
Sym-
Part No. Part name
bol
N 792-415-1200 Fixed valve assembly
a If the machine is disabled due to failure of a
transmission valve part (electrical system, sole-
noid valve, spool, etc.), installing the fixed valve
assembly (tool N1) allows the machine to move.
k If the machine cannot be moved in any gear
speed due to transmission control valve fail-
ure, installing the fixed valve assembly (tool
N1) to ECMV allows the machine to be moved
from a dangerous work site to a safe place
where repair can be conducted. Do not use
the fixed valve assembly for any other pur-
poses.
k When moving the machine by this method,
observe the procedure and ensure safety.
k Lower the work equipment completely to the
ground, apply the parking brake, and chock
the wheels to prevent the machine from mov-
ing.
k When releasing the parking brake, stop the
engine.
k When working while the oil temperature is
still high, take care not to get burn injury.
1. Open the transmission top cover.
2. Remove the valve cover.

a Remove mud and dirt from around the EC-
MV.
3. Disconnect the following wiring connectors: (1)

to (15) (CN-T3, T4, T5, T6, T7, T8, T11, T12,
T13, T14, T20, T21, T22, and T24).
a For precautions during removal of the wiring
connectors, see Disassembly and assembly,
"Removal of transmission control valve as-
sembly".
WA1200-6 30-33
Power train
4. Remove either of the two ECMV solenoids (15) 1) Assembly of fixed valve assembly (tool N1)
depending on the direction of travel (forward or 1] Install spring (17) to cover (16).
reverse), and install a fixed valve assembly (tool 2] Install the following spacer
N1) there. (18)(792-415-1120 stamped with R, 1, 2).
q For forward travel: F solenoid and 2nd sole- Required spacer (18)
noid
q For reverse travel: R solenoid and 2nd sole- Stamp R, 1, 2
noid
a If a wrong solenoid is removed, the transmis- a The fixed valve assembly (tool N1) in-
sion may break. Be careful. cludes
a Take care that mud or dirt will not enter the 792-415-1130 (spacer: stamped with
removed solenoids and valves. 3rd, H)
792-415-1140 (spacer: stamped with
4th, L), but these are not used on the
WA1200-6.
3] Install valve (19).

4] Install the O-ring to the fixed valve cover
mating surface with the proportional sole-
noid and ECMV.
30-34 WA1200-6
Power train
2) Using the tool N2, install the fixed valve

assembly (20) to ECMV.
3 Fixed valve assembly mounting
bolt:
13.2 ± 1.5 Nm {1.35 ± 0.15 kgm}
5. Fully depress the left brake pedal.
6. Start the engine and release the parking brake.
7. Slowly release the brake pedal to let the

machine start off and move.
k When the engine is started, the machine
starts to move through the transmission,
Before starting the engine, be sure to de-
press the brake pedal and ensure that
there are no persons or obstacles in the
direction of travel and around the ma-
chine.
WA1200-6 30-35
Power train
How to measure play of center hinge bearing
How to measure play of center hinge bearing 30-36

Procedure 1 30-36
Measuring clearance (play) of center hinge bearing
Measuring tool: Dial gauge
Preparation before measurement
1. Park the machine on a stiff and level ground.
2. Lower the bucket to the ground.
3. Apply the parking brake (turn ON).
4. Lock the front frame and rear frame by using frame lick bars.
5. Place a dial gauge on the front frame and an indicator on the rear frame.
Procedure 2 30-36
(1) Start the engine and raise the front tires from the ground. Under this condition, set the dial gauge to the
zero point.
Caution: Thoroughly check the safety around the machine, and do not raise the front tires too much.
30-36 WA1200-6
Power train
How to measure play of center hinge bearing
Procedure 3 30-37
(1) With the lift arm raised to the horizontal position, read the dial gauge (deflection).
Caution: Lock the work equipment control lever, and thoroughly check the safety around machine.
Procedure 4 30-37
1. Repeat measuring procedures 2 and 3 a few times to minimize variation in the data.
(1) 1st time mm (2) 2nd time mm (3) 3rd time mm
Measured value mm Standard value: 0.61 mm mm
2. Repair if out of standard.

(1) Adjustment by using shims (For details, see the shop manual for the applicable machine)
(2) If adjustment cannot be performed by using shims, replace bearing (upper and lower) and collar with
new parts. (For the procedure for replace,see"Disassembly and assembly"section)
WA1200-6 30-37
Power train
Measuring wear of rear axle support
Measuring wear of rear axle support 30-38

a Measure the amount of movement of the rear
axle according to the following procedure.
1. Fix magnet stand (1) to the support side.
2. With the rear wheels on the ground, set dial

gauge (2) to "0 mm".
3. Use two 30-ton jacks (3) to raise the rear wheels

off the ground and read the dial gauge.
a This dial gauge reading represents the clear-
ance between the axle and hole at the sup-
port side after the bushing is press fitted.
a If the dial gauge reading is 1.6 mm or more,
replace the bushing.
30-38 WA1200-6
Steering system
Testing and adjusting steering oil pressure

Testing and adjusting steering oil pressure 30-39
Measurement condition 30-39 Adjusting 30-39
q Hydraulic oil temperature: 45 to 55 °C k If the relief pressure is not correct, adjust the
k Be sure to follow "Safety precautions to fol- steering relief valve as follows.
low before starting work". k When adjusting, stop the engine.
1. Select "SERVICE MENU SELECT" on the multi
monitor screen. 1. Loosen lock nut (6) of steering relief valve (2)
and turn adjustment screw (7) to adjust the pres-
2. Use item selection switches F3 and F4 to select sure.
Pm Clinic, and then press F6 switch to display a Quantity of pressure adjustment per turn of
the "PM-CLINIC MENU" screen. adjustment screw
Per turn: Approx. 3.5 MPa {Approx.
35.7 kg/cm2}
a Turn the adjustment screw clockwise to in-
crease the set pressure.
a Do not perform any adjustment if the relief
pressure cannot be measured accurately.
3. Display item "S/T (steering) pump pressure"

(page 4/4 of "PM-CLINIC MENU" screen).
4. Start the engine and run at full speed. Measure

the oil pressure when the joystick lever is moved
to the right or left and the relief valve is oper-
ating.

value is released.
a The steering oil pressure sensor is installed
to the left steering valve.
WA1200-6 30-39
Steering system
Testing and adjusting emergency steering oil pressure
Testing and adjusting emergency steering oil pressure 30-40

a Testing tools 4. Remove oil pickup plug (5) (PT1/8) from
Sym- between the diverter valve and the steering
Part No. Part name valve. Install nipple "C2" and oil pressure gauge
bol
799-101-5002 Analog hydraulic tester "C1" (40 MPa {400 kg/cm2}).
1
C 790-261-1204 Digital hydraulic tester
2 799-101-5160 Nipple

k Loosen the oil filler cap to release the pres-
sure in the hydraulic tank.
a Two emergency diverter valves are installed at
the top and bottom.
1. Disconnect the propeller shaft between the
transmission and center support at the transmis-
sion end. 5. Start the engine and shift to 3rd speed forward
2. Disconnect the propeller shaft between the (or reverse). Increase the travel speed to 24
transmission and rear axle at the transmission km/h on the speedometer, turn the steering
end. wheel to the left or right, and measure the pres-
3. Disconnect diverter valve pilot hose (3), Replace sure when the relief valve is actuated.
elbow (4) with a pressure blocking elbow (see
next page) and install hose (3). Adjusting 30-40
a This blocks oil pressure to the diverter valve k When adjusting, stop the engine.
pilot port and the system is put in the emer- 1. Remove cap nut (6) of the relief valve.
gency steering mode.
30-40 WA1200-6
Steering system
Testing and adjusting emergency steering oil pressure
2. Loosen lock nut (7) and turn adjustment screw

(8) to adjust the pressure.
a Pressure adjustment per one turn of adjust-
ment screw
35.7 kg/cm2}
crease the set pressure, and turn it counter-
clockwise to decrease the pressure.
a Do not perform any adjustment if the relief
pressure cannot be measured accurately.
a Preparing the pressure blocking elbow

Prepare an elbow (07236-10210). Drive a 5
mm dia. pin into the drilled hole and weld it in
place to block the oil passage.
WA1200-6 30-41
Steering system
Bleeding air from steering circuit
Bleeding air from steering circuit 30-42

k Be sure to follow "Safety precautions to fol- 5. Run the engine at low idle.
low before starting work". 1) Slowly move each cylinder to the right and
a Bleed air from the circuit as follows if the steering left until they come to 100 mm before the
valve or steering cylinder have been removed stroke end.
and installed. q Never let the relief valves actuate.
q Steer alternately to right and left four or
1. Add oil to the hydraulic tank until the oil level five times.
reaches the upper limit G1 in the sight gauge. 2) Slowly move each cylinder to the right and
left to their stroke ends.
q Never let the relief valves actuate.
q Steer alternately to right and left four or
five times.
6. Stop the engine, loosen plugs (1) to (4), and

bleed air from the hydraulic oil filter case.
1) Loosen plugs slowly, one by one to bleed air.
2) When disassembling or reassembling the
work equipment, valves, or piping, check the
air bleeding plugs before starting the engine,
and replace any damaged plugs with new
ones.
2. Add oil again.400 l
3. Tighten cap (4).
7. Lower the bucket to the ground and check the oil

level. Add oil as necessary until the level
reaches the Full mark in the sight gauge (G1).
4. Start the engine and run at low idle for five
minutes.
Check for oil leaks.
a (Caution) Do not run the engine at high idle.
Do not operate the cylinder to its stroke end
before bleeding air (the cylinder may break).
30-42 WA1200-6
Steering system
Bleeding air from steering circuit
8. Run the engine at 1500 rpm and slowly move the

cylinder piston rods to their stroke ends.
Steer alternately to right and left four or five
times.
9. Stop the engine, loosen plugs (1) to (4) to bleed

air. (see No. 6)
10. Repeat No. 8 and No. 9 until the air is completely

bleeded.
11. When the air is completely bleeded, check the oil

reaches the Full mark in the sight gauge.
WA1200-6 30-43
Steering system
Testing and adjusting steering stopper bolt
Testing and adjusting steering stopper bolt 30-4

k Be sure to follow "Safety precautions to fol- 3) When clearance adjustment is complete,
low before starting work". tighten lock nut (4) of adjustment bolt (5).
a Standard length (b): 15 mm
1. With the engine running at low idle, steer to the
right or left. When clearance (a) between frame
end stopper (2) of front frame (3) and rear frame
(3) is out of the specified range, adjust it in the
a Clearance (a): 37 to 40 mm
3 Locknut:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
1) Loosen lock nut (4) and turn adjustment bolt

(5) to bring clearance (a) to the standard
value.
k Withe engine running at low idle, slow-
ly operate the joystick steering lever.
k Use care in this operation so that your
body or arm are not caught between
the front and rear frames.
2) Start and run the engine at low idle. Slowly
steer to full right or left, and make sure that
the clearance between frame end stopper (2)
of front frame (1) and rear frame (3) is within
the standard value range.
a Fasten with a screw at center of the ob-
long hole.
30-44 WA1200-6
Steering system
Adjusting steering follow-up linkage
Adjusting steering follow-up linkage 30-45

k Be sure to follow "Safety precautions to fol- 3. In this condition, measure the voltage at frame
low before starting work". angle potentiometer (2) and lever angle potenti-
ometer (4).
Adjusting 30-45 a Potentiometer voltage at neutral: 2.5 ± 0.3 V
1. Place the frame lock bar to the "LOCK" position
and set the machine in the straight travel posi- 4. If the voltage is not 2.5 ± 0.3 V, loosen mounting
tion. screws (3) and (5) of potentiometers (2) and (4),
and then turn each potentiometer to adjust the
voltage.
a For the adjustment procedure, see"Adjusting
installed position of potentiometer".
2. Adjust length "L" of steering follow up linkage (1)

to the specified length.
a Specified length L: 342 mm
WA1200-6 30-45
Steering system
Adjusting installed position of potentiometer 3. Check the value of the "AJSS lever potentiom-
(work in pair) 30-46 eter voltage" or "Frame potentiometer voltage"
a The installed position of the potentiometer can under the "Work equipment (controller)" and
be adjusted while watching the multi monitor dis- adjust the installed position of the potentiometer
play screen. to achieve the standard range.
1. Display the "SERVICE MENU SELECT" screen

of the service mode. Use the "F3" or "F4" switch
to select the function and the "F6" switch to
select "Real-time monitor".
a Lever angle potentiometer adjustment proce-

dure
Turning the potentiometer results in the output
voltage being varied in the range 0 to 5 V. Adjust
the installed positions of the upper and lower
2. Select "Work equipment (controller)" on the potentiometers so that the voltage is 2.5 ± 0.3 V
"Rear-time monitor" display screen and press at the neutral position.
the "F6" switch. Then, the AJSS item detailed 1) Note that the harness connectors of the lever
screen appears. and frame potentiometers are deutsche
connectors.
2) If the neutral voltage is faulty, check the
potentiometer for operating voltage on the
bench.
o Replace if there is any problem.
30-46 WA1200-6
Steering system
Offset angle automatic correction procedure for

lever angle and frame angle potentiometers 30-47
1. Display the "SERVICE MENU SELECT" o
"Adjustment menu" o "AJSS" o "AJSS Neutral
Position Adjustment" on the multi monitor.
Unit: V (voltage)
Leftmost Rightmost
Machine position NEUTRAL
position position
Frame angle volt-
0.7 ± 0.3 2.5 ± 0.3 4.3 ± 0.3
age
Lever angle volt-
4.3 ± 0.3 2.5 ± 0.3 0.7 ± 0.3
age
2. Place the machine body and the AJSS lever in

the straight-ahead position.
WA1200-6 30-47
Steering system
3. Operate the machine body as instructed on the After the transmission of the signal, the adjust-
screen and press "F6". This sends a set signal to ment current value is updated according to a
the work equipment controller. signal from the work equipment controller.
A message appears according to the command A change of the numeric value is displayed
(setting completed or setting failed) from the according to the work equipment controller. The
work equipment controller. multi monitor is not concerned with changes in
When the setting is completed: Finished the numeric value through button operations.
When the setting failed: Wrong Value If the "F1" switch is pressed, the screen returns
Until a command is received: Setting is to the adjustment menu (2) AJSS screen.
underway
Pressing "F6" sends a set signal to the work
5. Pressing "F6" displays the table pattern number

according to the information from the work
4. Pressing "F6" displays the adjustment current "-" is displayed until information is notified for the
value according to the information from the work first time after the screen appears.
equipment controller. Pressing "F6" sends an AJSS oil pressure
"---" is displayed until information is notified for command table pattern change signal to the
the first time after the screen appears. work equipment controller.
Pressing "F3" sends an UP signal to the work After the transmission of the signal, the pattern
equipment controller. number is updated according to a signal from the
After the transmission of the signal, the adjust- work equipment controller.
ment current value is updated according to a A change of the numeric value is displayed
signal from the work equipment controller. according to the work equipment controller. The
A change of the numeric value is displayed multi monitor is not concerned with changes in
according to the work equipment controller. The the numeric value through button operations.
multi monitor is not concerned with changes in If the "F1" switch is pressed, the screen returns
the numeric value through button operations. to the adjustment menu (2) AJSS screen.
Pressing "F4" sends a DOWN signal to the work
30-48 WA1200-6
Steering system
6. The main monitor issues a command to display

this screen at an abnormal end, but once the
screen appears, control is passed onto the multi
monitor (KOMTRAX Plus).
If the "F5" switch is pressed after the message is
confirmed, the adjustment menu (2) AJSS
screen appears.
If a communication failure with the controller
lasts for 0.5 seconds or more during adjustment,
the screen returns to the service menu screen
without showing the abnormal end screen.
WA1200-6 30-49
Steering system
Testing steering EPC valve
Testing steering EPC valve 30-50

a Testing tools
Sym-
Part No. Part name
bol
1
5 799-203-2440 Nipple

Testing 30-50
k Lock the front frame and rear frame by using
frame lock bars and chock the wheels to pre-
vent the machine from moving.
k Loosen the oil filler cap of the hydraulic tank
to release the pressure inside the hydraulic
tank, then operate the steering wheel two or
three times to release the remaining pres-
sure in the piping.
1. Remove oil pressure switch (3) from nipple (2) of

rotary valve (1) and install an oil pressure gauge.
2. With the engine running at low idle and the

steering lock lever in LOCK position, move the
steering lever slowly to right and left at near the
neutral position and then read the oil pressure
when it is at the minimum. If the pressure is out
of the standard value range, replace EPC valve
(4).
a EPC valve set pressure: (steering lever at
neutral) 0.9 to 1.1 MPa {9 to 11 kg/cm2})
a EPC valve minimum pressure: (steering le-
ver steered) 0.49 to 0.64 MPa {4.8 to
6.3 kg/cm2})
30-50 WA1200-6
Steering system
Testing steering EPC valve
WA1200-6 30-51
Steering system
Testing and adjusting steering surge cut valve oil pressure
Testing and adjusting steering surge cut valve oil pressure 30-52
a Testing tools
Oil pressure gauge kit (analog)
799-101-5002 (Pressure gauge: 60 MPa
1
C {600 kg/cm2})
790-261-1204 Oil pressure gauge kit (digital)
2 799-101-5160 q Nipple
5 799-203-2440 Nipple

k Park the machine on a level ground, apply
the parking brake, lower the bucket to the 2) When measuring the right steering valve oil
ground, and reserve a safe area. pressure, remove plug (4) from tube (3)
k Chock the wheels to prevent the machine
between the steering pump and steering
from moving. valve, install nipples C5 and C2, and then
connect oil pressure gauge C1 (60 MPa
frame lock bars.
{600 kg/cm2}) to nipple C2.
tank, then operate the steering lever two or
sure in the piping.
a The procedure is common for both sides except
for the location of the hydraulic pressure mea-
suring points.
a An oil pressure sensor (2) is installed on the left
steering valve.
Testing 30-52
1. Steering surge cut valve oil pressure must be
measured at the pump inlet side circuit of the
steering valve.
a Since the right and left steering valve pres- 2. Loosen lock nut (6) on steering main relief valve
sures are merged at the outlet side of the (5), and screw in the adjustment screw (7) half a
steering valve, right and left pressures can- turn.
not be measured separately at the outlet a Ensure that only surge cut valve (8) is al-
side. lowed to operate.
1) When measuring the left steering valve oil q Steering main relief valve set pressure:
pressure, remove steering oil pressure 31.0 to 31.9 MPa {316 to 325 kg/cm2}
sensor (2) from tube (1) between the steering q Surge cut valve set pressure:
pump and steering valve, install nipples C5
33.3 to 34.3 MPa {340 to 350 kg/cm2}
and C2, and then install oil pressure gauge
C1 (60 MPa {600 kg/cm2}) to nipple C2.
30-52 WA1200-6
Steering system
Testing and adjusting steering surge cut valve oil pressure
Adjusting 30-53
a If the surge cut valve (8) set pressure is not cor-
rect, adjust following the steps below.
k Stop the engine before adjusting the surge

cut valve.
1. Loosen lock nut (8) for the surge cut valve and
turn adjustment screw (10) to adjust the pres-
sure.
ment screw
3. Start and run the engine at low idle (650 rpm). Per turn: Approx. 17.8 MPa {181 kg/cm2}
Move the steering lever to left or right, and
measure the oil pressure when the surge cut
valve is actuated.
q Surge cut valve set pressure:
33.3 to 34.3 MPa {340 to 350 kg/cm2}
4. After measuring or adjusting the surge cut valve,

loosen adjustment screw (7) on the steering
main relief valve half a turn, tighten lock nut (6)
and adjust the steering main relief valve.
2. Do not perform any adjustment if the surge cut

valve set pressure cannot be measured.
a After adjustment of the surge cut valve, ad-
just the main relief valve.
a After testing, bleed air from the circuit and
check the oil level.
WA1200-6 30-53
Steering system
Testing and adjusting steering main relief valve oil pressure
Testing and adjusting steering main relief valve oil pressure 30-54
a Testing tools
799-101-5002 (pressure gauge: 60 MPa
1
C {600 kg/cm2})
2 799-101-5160 q Nipple
5 799-203-2440 Nipple
Measurement condition 30-54

the parking brake, lower the bucket to the 2) When measuring the right steering valve oil
ground, and reserve a safe area. pressure, remove plug (4) from tube (3)
between the steering pump and steering
from moving. valve, install nipples C5 and C2, and then
install oil pressure gauge C1 (60 MPa
frame lock bars.
sure in the piping.
suring points.
Checking 30-54
steering valve.
a Since the right and left steering valve pres-
sures are merged at the outlet side of the
steering valve, right and left pressures can- 2. Start the engine and run at high idle (engine
not be measured separately at the outlet speed: 2,050 rpm). Measure the oil pressure
side. when the steering lever is moved to the right or
1) When measuring the left steering valve oil left and the main relief valve is actuated.
pressure, remove steering oil pressure q Main relief valve set pressure:
sensor (2) from tube (1) between the steering 31.0 to 31.9 MPa {316 to 325 kg/cm2}
30-54 WA1200-6
Steering system
Testing and adjusting steering main relief valve oil pressure
Adjusting 30-5
a If the set pressure of main relief valve (5) is not
correct, adjust the main relief valve according to
the following procedure.
k Stop the engine before adjusting the main re-

lief valve.
1. Loosen lock nut (6) of the main relief valve and

turn adjustment screw (7) to adjust the pressure.
crease the set pressure and turn it counter-
ment screw
181 kg/cm2}
3 Locknut:
75 to 85 Nm {7.7 to 8.7 kgm}
2. Do not perform any adjustment if the main relief

valve set pressure cannot be measured accu-
rately.
WA1200-6 30-55
Steering system
Testing rotary valve output pressure
Testing rotary valve output pressure 30-56

a Testing tools
Oil pressure gauge kit (ana-
799-101-5002
1 log)
C
7 790-261-1331 q Adapter

frame lock bars.

to release the pressure inside the hydraulic 2. Install oil pressure gauge C1 to adapter C7.
three times to release the remaining pres- 3. Start and run the engine at low idle, and then
sure in the piping. slowly move steering lever (7) to the right and left
stroke ends.
Testing 30-56
1. To test the rotary valve output pressure, install 4. While holding steering lever (7), raise the engine
adapter C7 between hose (2) and nipple (3) that speed to high idle.
are located between rotary valve (1) and
steering demand valves (4), (5).
30-56 WA1200-6
Steering system
Testing rotary valve output pressure
5. Measure rotary valve output pressures P3 and a Rotary valve output pressure difference stan-
P4 at both ends of the steering valve, and calcu- dard value
late the difference. Conditions Standard value
q Hydraulic oil temperature: 3.53 to 4.11 MPa
45 to 55 °C {36 to 42 kg/cm2}
q Engine at high idle
Relationship between hydraulic system diagram and oil pressure at each part 30-57
WA1200-6 30-57
Brake system
Testing brake performance
Brake system 30-58

Testing brake performance 30-58
a Test the wheel brake performance under the following conditions.
q Road: Flat, level, paved, and dry road
q Braking initial speed: 20 km/h
2
q Tire inflation pressure: Specified pressure (MPa {kg/cm })
q Delay in applying brakes: 0.1 second
1. Start the engine, set the directional lever in the forward position, shift to 3rd speed, and start the machine.
2. Hold the travel speed at 20 km/h, and then depress the brake pedal with the specified operating effort.
a Decide the distance of the travelling and the measurement starting point in advance. Hold the travel
speed at 20 km/h, and then depress the brake pedal when the machine passes the measurement start-
ing point.
a Set transmission cut-off switch to ON.
3. Measure the distance from the measurement starting point to the point where the machine stops.
a Repeat this measurement three times and take the average.
30-58 WA1200-6
Brake system
Testing lowering of wheel brake oil pressure
Testing lowering of wheel brake oil pressure 30-59

a Testing tools
793-520-1805 Brake test kit
I
793-520-1851 q Nipple
k chock the wheels to prevent the machine
from moving.
1. Testing wheel brake oil pressure

1) Remove bleeder screw (1) and install oil
pressure gauge [40 MPa {400 kg/cm2}], joint,
bleeder screw, and nipple shown in testing
tool I.
2) Connect hose (2) to the bleeder screw and
then bleed air from the brake circuit. For
details, see "Bleeding air from each part".
3) Depress the left brake pedal and measure
the brake oil pressure.
2. Testing brake piston pressure drop

1) Remove bleeder screw (1) and install oil
pressure gauge [40 MPa {400 kg/cm2}], joint,
bleeder screw, and nipple shown in testing
tool I.
2) Connect hose (2) to the bleeder screw and
then bleed air from the brake circuit. For
details, see "Bleeding air from each part".
3) Stop the engine and depress the left brake
pedal to set the oil pressure to 15.5 MPa
{158 kg/cm2}. Hold this state for 5 minutes
and then measure the pressure drop.
WA1200-6 30-59
Brake system
Testing of slack adjuster
Testing of slack adjuster 30-60

a Testing tools 4. Then, read the maximum pressure (relief pres-
Symbol Part No. Part name sure) while holding down the brake pedal.
799-101-5002
Oil pressure gauge kit (ana- a Slack adjuster operating pressure standard
C 1 log) value
790-261-1204 Oil pressure gauge kit (digital) Check item Standard value
Check valve operating 1.69 to 1.79 MPa
Testing condition 30-60 pressure (cracking pres- {17.3 to 18.3 kg/cm2}
q Brake oil temperature: 45 to 55 °C
sure)
Maximum pressure 17.3 to 17.9 MPa
(relief pressure) {177 to 183 kg/cm2}
from moving. a Check also plug (4) same as described
above.
Checking 30-60 a Check both the front side and rear side of the
1. Release the remaining pressure in the brake slack adjuster.
circuit at bleeder (2) of slack adjuster (1).
2. Remove plug (3) and install oil pressure gauge

C1.
3. Run the engine at low idle and slowly depress

the brake pedal. Oil from port (A) pushes check
valve (5) and flows into port (B). Read the check
valve operating pressure at this moment on the
oil pressure gauge.
30-60 WA1200-6
Brake system
Mesuring wear of wheel brake disc
Mesuring wear of wheel brake disc 30-61

k Park the machine on a level ground and
chock the wheels to prevent the machine
from moving.
a Brake oil pressure: 15.4 ± 1.37 MPa {158 ±

14 kg/cm2}
1. Remove cap (1).
2. Depress the brake pedal to the travel end.
3. Press the end of shaft (2) until it touches the

plate.
4. Measure depth a from the end of shaft (2) to

guide (3) with vernier calipers M.
a Keep depressing the brake pedal during
measurement.
Wear limit: a = 7.0 mm max.
a If the disc wear approaches the wear limit,
check the condition frequently, regardless of
the maintenance interval.
WA1200-6 30-61
Brake system
Testing and adjusting accumulator charge pressure
Testing and adjusting accumulator charge pressure 30-62

k Be sure to follow "Safety precautions to fol- 4. Measure the accumulator charge cut-out pres-
low before starting work". sure. Measure the oil pressure when the rising
oil pressure alters to drop.
Measurement 30-62 Cut-out pressure: 20.6 to 22.1 MPa {210 to
q Brake oil temperature: 45 to 55 °C 225 kg/cm2}
k Stop the engine, then depress the brake ped- 5. Measure the accumulator charge cut-in pres-
al at least 100 times to release the pressure sure. Start the engine and run at low idle. While
inside the accumulator circuit. observing the pressure fall, measure the
1. Select "SERVICE MENU SELECT" on the multi minimum pressure when the oil pressure gradu-
monitor screen. ally alters from fall to rise (read the F brake pres-
2. Use item selection switches F3 and F4 to select sure or R brake pressure on the multi monitor).
Pm Clinic, and then press F6 switch to display Cut-in pressure: 17.6 to 18.2 MPa {180 to
186 kg/cm2}
3. Display item "F brake pressure" or "R brake
pressure" (page 4/4 of "PM-CLINIC MENU"
screen).
value is released.
30-62 WA1200-6
Brake system
Testing and adjusting accumulator charge pressure
Adjusting 30-63
Accumulator charge cut-in pressure and cut-out
pressure
a When the accumulator charge cut-out pressure
is adjusted, the cut-in pressure also changes in
proportion to the valve area ratio. Therefore, a
cut-in pressure adjustment screw is not provid-
ed.
1. Loosen lock nut (5) of cut-out valve (4), then turn
adjustment screw (6) to adjust the pressure.
a If the adjustment screw is
q Turned clockwise, the pressure is in-
creased.
q Turned counterclockwise, the pressure is
decreased.
a Quantity of pressure adjustment per turn of
adjustment screw:
5.59 MPa {57 kg/cm2}
3 Locknut:
9.8 to 11.8 Nm {1 to 1.2 kgm}
a After completion of adjustment, repeat the
measurement procedure given above to
check the accumulator charge cut-in and
cut-out pressures again.
WA1200-6 30-63
Brake system
Testing brake accumulator oil pressure leakage
Testing brake accumulator oil pressure leakage 30-64

k Be sure to follow "Safety precautions to fol- 4. Disconnect hose (3) between tube (2) of emer-
low before starting work". gency parking brake valve (1) and the accumu-
k Lock the front frame and rear frame by using lator.
frame lock bars.
Testing 30-64
q Start and run the engine until the charge pres-
sure reaches the following value, and then stop
the engine. The pressure must not drop below
14.7 MPa {150 kg/cm2} within 15 minutes.
Charge pressure
2
q New machine: 17.6 MPa {180 kg/cm }
q Used machine: 20.6 MPa {210 kg/cm }

2
a Check the charge pressure at "F brake oil pres-

sure" or "R brake oil pressure" (page 4/4 of
"PM-CLINIC MENU" screen) of the multi moni-
tor.
5. Securely install plug (4) and O-ring (5) to discon-
nected tube (2), and install cap (6) to hose (3).
q Part number of parts installed to tube:
07376-70422 plug (4)
02896-11012 O-ring (5)
q Part number of parts installed to hose:
02789-10422 cap (6)
1. Stop the engine.

2. Turn the starting switch to the "ON" position (do
not start the engine) and set the multi monitor
screen to "F brake oil pressure" or "R brake oil
screen).
3. Repeatedly depress and release the right and
left brake pedals to lower the brake oil pressure
to 0 MPa {0 kg/cm2}.
k Thoroughly remove the remaining pres-
sure.
30-64 WA1200-6
Brake system
Testing brake accumulator oil pressure leakage
6. Start and run the engine until the charge pres-

Charge pressure
2
2
7. When the test is completed, lower the brake oil
pressure to 0 MPa {0 kg/cm2} by referring to
steps 1 to 3.
sure.
8. Reconnect hose (3) to tube (2).
9. If the pressure dropped below 14.7 MPa
{150 kg/cm2}, check for leaks from the emer-
gency parking brake valve.
WA1200-6 30-65
Brake system
Testing emergency parking brake valve oil leakage amount
Testing emergency parking brake valve oil leakage amount 30-6

k Be sure to follow "Safety precautions to fol- Preparation 30-6
low before starting work". a Prepare an oil container to collect the brake oil
k When starting the engine, always work in a flowing out and a measuring cylinder.
group of two, and do not go under the ma- 1. Disconnect return hose (2) of emergency
chine. Also, check the safety before starting parking brake valve (1) from tube (3), and install
the work. sleeve nut and plug [1] to tube (3).
q [1] Part number: 07221-20422 Sleeve nut
Releasing remaining pressure from the brake : 07222-00414 Plug
accumulator 30-6 a Place an oil container to collect the brake oil
1. Stop the engine. flowing out.
screen).

sure.
2. Start the engine, check that the pressure has

reached the accumulator charge valve cut-out
pressure on the multi monitor, and then stop the
engine.
q Accumulator charge valve cut-out pressure:
20.6 to 22.1 MPa {210 to 225 kg/cm2}

k Always stop the engine before taking
measurements.
k When starting the engine, always work in
a group of two, and do not go under the
machine. Also, check the safety before
starting the work.
30-66 WA1200-6
Brake system
3. Collect the brake oil that flows out from the

disconnected return hose (2) in a measuring
cylinder [2] and check the amount of leakage
during one minute.
Leakage amount standard value
q Max. 80 cc/minute (brake oil temperature: 45
to 55 °C)
q Max. 233 cc/minute (brake oil temperature:
75 to 85 °C)
4. If the leakage exceeds the standard value,

replace or repair the emergency parking brake
valve.
5. Remove the sleeve nut and plug [1] from tube
(3), and install return hose (2).
WA1200-6 30-67
Brake system
30-68 WA1200-6
Brake system
Testing brake valve oil leakage amount
Testing brake valve oil leakage amount 30-69

k Be sure to follow "Safety precautions to fol- Preparation 30-69
low before starting work". q Prepare an oil container to collect the brake oil
k Park the machine on a level ground, apply flowing out and a measuring cylinder.
the parking brake, lower the bucket to the
ground, and reserve a safe area. Measuring left brake valve (single) oil leakage
k chock the wheels to prevent the machine amount 30-69
from moving. 1. Disconnect drain hose (2) of left brake valve (1)
at elbow (4) side of tube (3).
Releasing remaining pressure from the brake a Place an oil container to collect the brake oil
accumulator 30-69 flowing out.
1. Stop the engine.
pressure" (page 4/4 of "PM-CLINIC MENU
screen).

sure.
2. Install a sleeve nut and plug [1] to elbow (4) to

block the counterflow of oil from the brake oil
tank.
q [1] Part number: 07221-20422 Sleeve nut
: 07222-00414 Plug
WA1200-6 30-69
Brake system
3. Start the engine, check that the pressure has Measuring right brake valve (tandem) oil leakage
reached the accumulator charge valve cut-out amount 30-70
pressure on the multi monitor, and then stop the 1. Stop the engine.
engine. 2. Disconnect tube (3) from the drain port of right
k Never depress the brake pedal. brake valve (5).
q Accumulator charge valve cut-out pressure: a Place an oil container to collect the brake oil
20.6 to 22.1 MPa {210 to 225 kg/cm2} flowing out.
4. Collect the brake oil that flows out from the a Remove hose (2) without disconnecting it
disconnected drain hose (2) in a measuring from tube (3).
cylinder [2] and check the amount of leakage a Leave elbow (6) and connector (7) on right
during 1 minute. brake valve (5).
Leakage amount standard value < brake oil
temperature: 50 °C >
q New brake valve: 42 cc/minute
q Brake valve replacement standard: 42
cc/minute
Reference < brake oil temperature: 80 °C >
q Brake valve replacement standard: Min. 160
cc/minute
3. Install plug [3] to tube (3) to block the counterflow

of oil from the brake oil tank.
q Plug [3] part number: 07376-70628
5. If the leakage exceeds the replacement stan-

dard, replace the left brake valve assembly or
seals.
4. Start the engine, check that the pressure has

pressure on the multi monitor, and then stop the
engine.
q Accumulator charge valve cut-out pressure:
20.6 to 22.1 MPa {210 to 225 kg/cm2}
30-70 WA1200-6
Brake system
5. Connect a vinyl tube (inside diameter: 30 mm)

[4] to connector (7) of the right brake valve.
Collect the leaked brake oil in a measuring
cylinder [2] and check the amount of leakage
during 1 minute.
Leakage amount standard value < brake oil
temperature: 50 °C >
cc/minute
Reference < brake oil temperature: 80 °C >
cc/minute
6. If the leakage exceeds the replacement stan-

dard, replace the right brake valve assembly or
seals.
WA1200-6 30-71
Brake system
Brake hydraulic circuit diagram 30-72
30-72 WA1200-6
Brake system
WA1200-6 30-73
Brake system
Testing brake cooling oil pressure
Testing brake cooling oil pressure 30-74

a Testing tools
799-101-5002 (pressure gauge: 2.5 MPa
1
C {25 kg/cm2})
3 790-301-1271 q Joint

q Engine speed: High idle (2,050 rpm)
q Brake cooling oil temperature: 80 °C
1. Preparation 2. Testing
q In order to test the brake cooling oil pressure, 1) Stop the engine.
remove tubes (3) and (4) from blocks (1) and k Loosen the brake oil tank cap to re-
(2). Drill and tap oil pressure pickup holes (10 lease the pressure inside the tank.
mm dia., thread pitch 1.25 mm) at portion "B" 2) Remove two plugs from the drilled and
of tubes (3) and (4). tapped holes (M10 P1.25) and install joints
a Part number of plug installed to tapped C3 to each hole. Connect oil pressure
hole:
gauges C1 (2.5 MPa {25 kg/cm2}) to joints
07040-11007: Plug
C3.
07002-21023: O-ring
3) Start the engine, and check if are within the
standard value at the engine speed. The oil
pressures at block (1) and (2).
q Block (1) side oil pressure standard val-
ue:
0.23 to 0.35 MPa {2.4 to 3.6 kg/cm2}
a If the pressure is out of the standard
range, check the pressure valve.
q Block (2) side oil pressure standard val-
ue:
0.13 to 0.17 MPa {1.3 to 1.7 kg/cm2}
q Difference pressure between block (1)
and (2):
0.1 to 0.2 MPa {1 to 2 kg/cm2}
30-74 WA1200-6
Brake system
Testing brake cooling oil pressure
4) When all measurements are completed, stop

the engine and install plugs to blocks.
WA1200-6 30-75
Brake system
Testing brake oil cooler performance
Testing brake oil cooler perfor- Testing parking brake perfor-

mance 30-76 mance 30-76
a Testing tools a Test the parking brake performance under the
Sym- following conditions.
Part No. Part name
bol
B 799-101-1502 Digital thermometer kit q Tire inflation pressure: Specified pressure
k Be sure to follow "Safety precautions to fol- q Road: 1/5 gradient (11 deg. 20'), flat, and dry
low before starting work". road
q Machine: Ready for operation
a To test the brake oil cooler performance, mea-
sure the temperature at the inlet and outlet of the 1. Start the engine and set the machine in the
brake oil cooler and calculate the difference. straight travel position, and then drive up a slope
of 1/5 gradient with no load in the bucket.
1. Stop the engine.
2. Remove plugs (4) from tubes (1) and (2) at their

brake oil cooler (3) side, and install oil tempera-
ture gauges to two places.
2. Depress the brake pedal, move the directional

lever in the "NEUTRAL" position, and stop the
engine.
3. Turn the parking brake switch ON, and then

3. Start the engine and check the temperature release the brake gradually. At this time, the
difference between the brake oil cooler inlet and machine must not move.
outlet. a Measure the parking brake performance on
a Temperature difference: 14 °C an uphill and a downhill.
4. When all measurements are completed, stop the

engine and install plugs (4).
30-76 WA1200-6
Brake system
Testing wear of parking brake disc
Testing wear of parking brake disc 30-7

a If the parking brake does not work effectively, 5. If the parking brake disc (5) thickness is below
check the parking brake disc for wear according the standard value, replace the disc.
to the following procedure. q Standard depth (a): Max. 46.3 mm
k Be sure to follow "Safety precautions to fol- q Repair limit depth (reference value): Max.
low before starting work". 51.6 mm
k Lower the work equipment completely to the
ground and chock the wheels to prevent the
machine from moving.
k When checking, stop the engine.
1. Drain oil from the transmission case.

6 Transmission case
approx. 350 l
2. Remove one of the two plugs (1).
3. Measure depth (a) from the end of cage (2) to

the piston with vernier calipers [1].
4. If depth (a) is above the standard, remove

parking brake disc (4) and measure its thickness
(W), referring to Disassembly and assembly,
"Removal of parking brake disc (5)".
q Standard thickness: (W) = 3.2 ± 0.1 mm
WA1200-6 30-77
Brake system
Method of releasing parking brake manually
Method of releasing parking brake manually 30-78

a The parking brake is controlled hydraulically. If q Set of 16 discs
you cannot release the parking brake because of
a trouble in the transmission, emergency release
solenoid valve, etc., you can move the machine
by releasing the parking brake manually.
k Releasing the parking brake manually is a
means to move the machine from a danger-
ous job site to a safe place. Apply this means
only in an emergency.
k Lower the work equipment to the ground and
chock the wheels to prevent the machine
from moving.
k When checking, stop the engine.
Refilling
1. Drain oil from the transmission case.
6 Transmission case
q Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
approx. 350 l
system. Then, check the oil level again.
2. Remove 2 plugs (1).
3. Remove two cage mounting bolts (2), and

tighten them alternately in plug installation posi-
tions.
a Remove one bolt (2) and a washer together
on the diagonal position.
a Tighten bolts (2) to pull piston (3) and release
the parking brake.
a Tighten the two bolts gradually and evenly.
a The brake will be released when the bolts are
tightened further for about 6 1/2 turns after
the bolts and washers are seated.
30-78 WA1200-6
Brake system
Testing parking brake oil pressure
Testing parking brake oil pressure 30-79

Testing parking brake inlet pressure 30-79 a Parking brake solenoid inlet pressure standard
a Testing tools value
Sym- Conditions Standard value
Part No. Part name
bol q Torque converter oil temperature: 2.45 to 2.85 MPa
799-101-5002 Analog hydraulic tester 60 to 80 °C {25 to 29 kg/cm2}
1 q Engine speed: At high idle
3 790-301-1271 Joint
a Torque converter oil temperature: 60 to 80 °C

from moving.
1. Remove oil pressure pickup plug (M10 P1.25)

(1) and install oil pressure gauge C1 (6 MPa
{60 kg/cm2}).
2. Turn parking brake switch OFF.
3. Start the engine and test the oil pressure at high

idle.
a Parking brake inlet pressure standard value

q Torque converter oil temperature: 2.45 to 2.85 MPa
60 to 80 °C {25 to 29 kg/cm2}
q Engine speed: At high idle
Testing parking brake solenoid inlet pressure 30-79

a Testing tools
Sym-
Part No. Part name
bol
1
4 790-261-1311 Adapter
a Torque converter oil temperature: 60 to 80 °C

k chock the wheels to prevent the machine
from moving.
k Stop the engine, then depress the brake ped-
al at least 100 times to release the pressure
inside the accumulator circuit.
1. Turn the starting switch ON and the parking

brake switch OFF to release the brake.
2. Disconnect hose (2) and install the adapter and

oil pressure gauge C1 (6 MPa {60 kg/cm2}) of
tool C1.
3. Start the engine and test the oil pressure at high

idle.
WA1200-6 30-79
Brake system
Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Testing accumulator nitrogen gas pressure and procedure for charging

accumulator with nitrogen gas 30-80
a Testing and adjusting tools Precautions when connecting the gas charge
Sym- Applicable tool R1 30-80
Part No. Part name
bol standard 1. Sealant has been applied to the threaded portion
792-610-1701 Gas charge tool kit of the adapter (5) for the gas charge tool R1.
For old type
792-610-1700 q Gas charge tool Never attempt to remove it unless absolutely
ACC
07000-11009 q O-ring
necessary. Otherwise, the gas may leak out.
1 792-610-1702 Gas charge tool kit
792-610-1700 q Gas charge tool For old and 2. On some gas valves (4), the length of the
07000-11009 q O-ring new type ACC threads (B) may be not long enough for the
792-610-2310 q Extension depth (A) from the end face of the adapter (5) to
Nipple the packing (6) of the gas charge tool R1,
792-610-1310 GOST
(For Russia) preventing the gas valve (4) from seating
Nipple completely. In such a case, nitrogen gas may
R 792-610-1320 CGA No.351
(For USA) leak out through the threads of the gas valve (4).
Nipple ASA
792-610-1330 3. When connecting the gas charge tool R1 to the
2 (For USA) B-571-1965
DIN 477-1963 gas valve (4) but the extension (P/N:
NEN3268- 792-610-2310) supplied with the tool is not avail-
Nipple able, install O-ring (7) (P/N: 07000-11009)
792-610-1350 1966
(For Germany) supplied with the tool to gas valve (4). Connect
SIS-SMS
2235/2238 the gas charge tool R1. Then, check to ensure
Nipple BS 341 that there is no leakage.
792-610-1360
(For UK) Part1-1962
k Put on proper protection gear (goggles,
leather gloves and protective clothes) so that
the leaking nitrogen gas will not touch your
skin or clothes and work on the windward
side as long as possible.
k When handling nitrogen gas in a room or an-
other place which is not ventilated well, ven-
tilate the work place forcibly and observe the
Oxygen Deficiency Prevention Rules of the
Labor Safety and Sanitation Law.
k The accumulator is charged with high-pres-
sure nitrogen gas, so mistaken operation 4. If extension (8) (P/N: 792-610-2310) supplied
may cause an explosion, which will lead to with the tool is available, install extension (8) to
serious injury or damage. When handling the gas valve (4) and then connect gas charge tool
accumulator, strictly observe the following. R1.
q Do not bring fire near the accumulator or put a The O-ring supplied with the tool will not be
the accumulator in fire. used.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it of
the nitrogen gas.
q Before disassembly or removal, relieve the
accumulator charge down to the atmospheric
pressure.
q Only use nitrogen gas to fill the accumulator.
Do not use oxygen or other explosive gas.
q When handling the accumulator, strictly ob-
serve the precautions given in this manual.
30-80 WA1200-6
Brake system
Testing nitrogen gas pressure in accumulator 30-81 3) Install the extension (8) (P/N: 792-610-2310)
a The measuring is also possible on the accumu- supplied with the tool to the gas valve (4) by
lator alone. referring to "Precautions when connecting
a Nitrogen gas cylinder (c) must be connected the gas charge tool R1" Alternatively, install
even when you measure only the gas pressure. the O-ring (7) (P/N: 07000-11009) supplied
1. Stop the engine and depress the brake pedal with the tool to the gas valve (4).
repeatedly to lower the oil pressure in the brake a The O-ring is not used when installing the
circuit to zero. extension.
a Generally, if the brake pedal is depressed 30
times, the reaction force to the brake pedal is
lost and the oil pressure is lowered to zero.
2. Remove valve guard (2) and cap (3) from accu-
mulator (1). (Old type accumulator)
4) Connect gas charge tool R1 to gas valve (4)

on accumulator (1).
3. Remove plug (9) from accumulator (1).

(New type accumulator)
4. Connect the gas charge tool R1 to the gas valve

(4) on the accumulator (1) following the steps
below.
1) Turn the handle (a) on the gas charge tool R1
fully counterclockwise.
2) Close the valve of nitrogen gas cylinder (c)
and handle (b).
WA1200-6 30-81
Brake system
5) Connect gas charge tool R1 to nitrogen gas 6. If the gas pressure is too high or too low, adjust
cylinder (c). it referring to "Procedure for charging accumu-
a Avoid applying bending load to the gas lator with nitrogen gas".
valve (4), which may otherwise break. a Each time the pressure is measured, some
a There are 2 types of threads of nitrogen nitrogen gas is discharged and the pressure
gas cylinders, W23-14 thread (mail lowers. Add nitrogen gas by the loss.
screw, type A) and W23-14 thread (fe-
male screw, type B). When using a gas 7. Turn handle (a) on the charge tool R1 fully coun-
cylinder of W23-14 thread (female screw, terclockwise.
type B), connect the hose by using the
adapter. (The adapter is supplied with the 8. Remove gas charge tool R1 from accumulator
gas charge tool R1.) (1) and restore the machine. Refer to "Procedure
for charging accumulator with nitrogen gas".
5. Slowly turn clockwise handle (a) of gas charge
tool R1 and read the gauge.
a Since the indicated value varies with the am-
bient temperature, refer to the following table
and check gas pressure.
(The unit of each value in the formula is °C.)
Indicated gas pressure = Standard gas
pressure x ((273 + t)/(273 + 20))
Quick reference table for gas pressure in the
accumulator
Ambient Gas pressure
Remarks
temperature °C MPa kg/cm2
15 4.34 44.2
16 4.35 44.4
17 4.37 44.5
18 4.38 44.7
19 4.40 44.8
Standard gas
20 4.41 45.0
pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.70 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
t: Gas temperature when charging ( °C)
Reference: t may be assumed to be ambient
temperature.
30-82 WA1200-6
Brake system
Procedure for charging accumulator with nitro-

gen gas 30-83
a The accumulator can also be charged in a simi-
lar manner when it is separate from the machine.
1. Stop the engine and depress the brake pedal
repeatedly to lower the oil pressure in the brake
circuit to zero.
4) Connect the charge tool R1 to gas valve (4)

on accumulator (1).
5) Connect gas charge tool R1 to nitrogen gas
cylinder (c).
Important
a Avoid applying bending load to the gas
valve (4), which may otherwise break.
q Use nipple R2 to connect the hose de-
pending on the specification of the nitro-
gen gas cylinder.

4. Following the steps below, connect gas charge

tool R1 and a nitrogen gas cylinder (c) to gas
valve (4) on accumulator (1).
1) Turn handle (a) on gas charge tool R1 fully
counterclockwise.
2) Turn handle (b) to the left to open.
3) Install extension (8) (P/N: 792-610-2310)
supplied with the tool to gas valve (4) by
referring to "Precautions when connecting
the gas charge tool R1". Alternatively, install
the O-ring (7) (P/N: 07000-11009) supplied
with the tool to the gas valve (4).
a The O-ring is not used when installing the
extension.
WA1200-6 30-83
Brake system
5. Slightly open the valve on the nitrogen gas t: Gas temperature when charging ( °C)
cylinder (c) to discharge nitrogen gas at a pres- Reference: t may be assumed to be ambient
sure of approx. 0.19 to 0.29 MPa {2 to 3 kg/cm2}. temperature.
6. After nitrogen gas starts flowing out of handle
(b), close handle (b) by turning it to the right. 10. After the accumulator is charged to the standard
7. Turn handle (a) slowly to the right to open valve pressure, close the valve of nitrogen gas
(4) of accumulator (1) gradually. cylinder (c).
a If handle (a) is turned too much, the valve q If the accumulator is charged too much, turn
core of the accumulator will be damaged and handle (b) to the left slowly with the valve of
gas will leak. Accordingly, operate handle (a) nitrogen gas cylinder (c) closed to release
carefully. the nitrogen gas gradually to adjust.
8. Open the valve of nitrogen gas cylinder (c) 11. Remove gas charge tool R1 from gas valve (4)
further to charge the accumulator with nitrogen of accumulator (1) according to the following
gas. procedure.
9. During the work, close the valve of nitrogen gas 1) Turn handle (a) to the left to close the valve
cylinder (c) and check the nitrogen gas pressure of the accumulator.
in the accumulator. 2) Turn handle (b) to the left to open and
a Since the indicated value varies with the am- discharge nitrogen gas remaining in gas
bient temperature, refer to the following table charge tool R1 and hoses.
to charge gas pressure in the cylinder. 3) Remove gas charge tool R1 from gas valve
(The unit of each value in the formula is °C.) (4) on the accumulator.
Indicated gas pressure = Standard gas 4) Remove extension (8) from gas valve (4).
pressure x ((273 + t)/(273 + 20)) Alternatively, remove O-ring (7) from gas
Quick reference table for gas pressure in valve (4).
the accumulator 12. Apply soap water to gas valve (4) of the accumu-
Ambient Gas pressure lator to ensure that nitrogen gas is not leaking.
Remarks 13. Install plug (9) to accumulator (1).
temperature °C MPa kg/cm2
15 4.34 44.2 3 Plug:
16 4.35 44.4 73.5 to 98.0 Nm {7.5 to 10.0 kgm}
17 4.37 44.5
18 4.38 44.7
19 4.40 44.8
Standard gas
20 4.41 45.0
pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.70 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
30-84 WA1200-6
Brake system
14. Within a week after charging the accumulator

with nitrogen gas, check the operation of the
brakes following the steps below to ensure that
the nitrogen gas charge has not dropped.
a Check the function within 5 minutes of stop-
ping the engine. (If more than five minutes
pass after the engine is stopped, oil pressure
in the brake circuit drops too much to effect
an accurate check.)
1) Stop the machine on a level ground and set
the parking brake switch in the "PARK" posi-
tion.
2) Start the engine and run it at medium speed
for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and depress the brake pedal repeatedly.
Count the number of depresses until the
brake oil pressure caution lamp lights up.
q Less than 5 depresses: Accumulator gas
charge may have dropped too much.
q 5 depresses or more: Accumulator gas
charge is at a correct level.
WA1200-6 30-85
Hydraulic system
Testing and adjusting work equipment oil pressure by using multi monitor

Testing and adjusting work equipment oil pressure by using multi
monitor 30-86
k Be sure to follow "Safety precautions to fol- 3) Press F6 on an item in "Work equipment" to
low before starting work". display "Pressure at the moment".
Checking 30-86 4) Start the engine, slowly raise the lift arm to
1. Measurement of work equipment relief pressure the stroke end, and then perform a lift arm
1) Select "SERVICE MENU SELECT" on the raise operation with the engine running at full
multi monitor screen. speed. Read the oil pressure when the relief
valve actuates on the "Pressure at the
moment" screen.

select Real-time monitor, and then press F6
switch to display the "Real-time monitor" 2. If [F3] switch is pressed while reading the oil
screen. pressure, the value is held.
value is released.
Note) The work equipment oil pressure
displayed on the multi monitor is the pressure of
the oil from three main valves after they are
merged. If the oil pressure is abnormal, test the
oil pressure at each valve, referring to "Trouble-
shooting of work equipment oil pressure
(20-1001-41–58)".
a The work equipment oil pressure displayed
on the multi monitor is the pressure of the oil
from three valves after they are merged.
30-86 WA1200-6
Hydraulic system
Testing and adjusting work equipment oil pressure by using multi monitor
Adjusting 30-87
1. Adjusting work equipment relief valve
k When adjusting the oil pressure, stop the
engine.
1) Loosen lock nut (3) of work equipment relief
valve (2), then turn adjustment screw (4) to
adjust.

creased.
q Turned counterclockwise, the pres-
sure is decreased.
a Quantity of pressure adjustment per turn
of adjustment screw:
1.02 MPa {10.39 kg/cm2}
a After completing adjustment, measure
the work equipment relief pressure again
according to the measurement procedure
above.
WA1200-6 30-87
Hydraulic system
Testing and adjusting work equipment oil pressure by using oil pressure gauge
Testing and adjusting work equipment oil pressure by using oil pressure
gauge 30-8
a Testing tools
Sym-
Part No. Part name
bol
1
3 790-301-1271 Joint
a To test the relief pressure of each control valve,

install an oil pressure gauge to the pressure
pickup plug at the pump delivery port side piping.
k Be sure to follow "Safety precautions before
starting work".
the parking brake, lower the bucket to the q No. 3 control valve (switch pump rear pump
ground, and reserve a safe area. side): 3B (thread size: M10 x 1.25)
k Stop the engine, then loosen the oil filler cap q No. 3 control valve (switch pump front pump
to release the pressure in the hydraulic tank. side): 3A (thread size: M10 x 1.25)
a For the layout drawing, see 20-136-6 to
20-136-7-2.
Testing 30-8
1. Remove the oil pressure pickup plug corre-
sponding to the control valve and install an oil
pressure gauge (60 MPa).
q No. 1 control valve (work equipment pump
No. 1 rear pump side): 1B (thread size: M10
x 1.25)
No. 1 front pump side): 1A (thread size: M10
x 1.25)
2. Start the engine, raise the lift arm, run the engine
at high idle, and then operate the bucket.
Measure the pressure when the relief valve is
actuated.
Note) Referring to "Troubleshooting of work
equipment oil pressure (20-1001-41–58)", test
oil pressures to check if the pumps and valves
are normal.
Adjusting 30-8
a For the adjustment procedures, see "Testing
and adjusting work equipment oil pressure by
using the multi monitor".
No. 2 rear pump side): 2B (thread size: M10
x 1.25)
No. 2 front pump side): 2A (thread size: M10
x 1.25)
30-88 WA1200-6
Hydraulic system
Testing and adjusting work equipment PPC oil pressure
Testing and adjusting work equipment PPC oil pressure 30-89

q Hydraulic oil temperature: 45 to 55 °C 5) If [F3] switch is pressed while reading the oil
k Be sure to follow "Safety precautions to fol- pressure, the value is held.
low before starting work". a If the hold [F3] switch is pressed again,
k Loosen the oil filler cap slowly to release the the value is released.
pressure inside the hydraulic tank.
k Operate the work equipment control lever 2. Measuring PPC pressure difference between
two to three times to release the pressure both ends of main valve
from the PPC accumulator circuit. 1) Remove the work equipment valve cover.
2) Remove oil pressure pickup plugs (M20x1.5)
Measurement 30-89 (1) to (4) for each circuit and install nipples
1. Measuring PPC relief pressure C3-1, C2 and oil pressure gauge C1 (6 MPa
1) Select "Service Menu" on the multi monitor {60 kg/cm2}).
screen. 1. For lift arm RAISE 3. For bucket DUMP
2. For lift arm LOWER 4. For bucket CURL
k Since the PPC circuit has been disas-
sembled and reassembled to install
the oil pressure gauge, bleed air from
the circuit.
3) Start the engine, raise the lift arm to the
stroke end, and run the engine at full speed.
Measure the oil pressure when the relief
valve is actuated.
PPC oil pressure:
3.72 to 3.92 MPa {38 to 40 kg/cm2}
Opposite side PPC oil pressure:
0 to 0.29 MPa {0 to 3 kg/cm2}
3) Display item "PPC oil pressure" (page 4/4 of

4) Start the engine and measure the oil pres-

sure with the engine running at full speed.
WA1200-6 30-89
Hydraulic system
Adjusting 30-90
1. Adjusting PPC relief valve
k Stop the engine before adjusting the ad-
justment screw.
1) Remove the cover at the top of the transmis-
sion.
2) Loosen lock nut (6) of PPC relief valve (5),
then turn adjustment screw (7) to adjust.
creased.
sure is decreased.
1.02 MPa {10.39 kg/cm2}
3 Locknut:
29.4 to 39.2 Nm {3 to 4 kgm}
3) When completing adjustment, test the PPC

oil pressure again on the multi monitor.
a After the first adjustment, there is a possi-
bility that the set pressure is too high.
Therefore, raise the engine speed gradu-
ally to avoid generation of abnormal pres-
sures in the circuit.
4) If the set pressure does not reach the speci-

fied value when the adjustment screw is
tightened, the relief valve is worn on the
inside. Replace the valve with a new one.
30-90 WA1200-6
Hydraulic system
Measuring point of hydraulic pump oil pressure
Measuring point of hydraulic pump oil pressure 30-91

a Oil pressure measuring points are shown in the drawing below.
WA1200-6 30-91
Hydraulic system
a Oil pressure measuring points are shown in the drawing below.
30-92 WA1200-6
Hydraulic system
Work equipment pump line 30-93

a Hydraulic piping are shown in the drawing below.
WA1200-6 30-93
Hydraulic system
Switch pump, steering pump lines 30-94

a Hydraulic piping are shown in the drawing below.
30-94 WA1200-6
Hydraulic system
Testing and adjusting PV control relief valve oil pressure
Testing and adjusting PV control relief valve oil pressure 30-95

a Testing tools Testing 30-95
Symbol Part No. Part name 1. Stop the engine.
Oil pressure gauge kit (analog) k Operate the work equipment control lever
799-101-5002 (pressure gauge: 6 MPa to release the pressure from the work
1
C {60 kg/cm2}) equipment PPC accumulator.
790-261-1204 Oil pressure gauge kit (digital) 2. Remove plug (2) (PT1/8) from block (1), install
2 799-101-5160 q Nipple nipple C2, and then connect oil pressure gauge
C1 (6 MPa {60 kg/cm2}).
ground, and reserve a safe area.
from moving.
k Stop the engine, then loosen the oil filler cap
to release the pressure in the hydraulic tank.
q The PV control relief valve controls the servo
valve maximum pressure of each work equip-
ment pump.
PV valve set pressure: 2.9 MPa {30 kg/cm2} 3. Start the engine and measure the oil pressure
while running the engine at high idle (2,050 rpm)
to check if the pressure is within the standard
value range.
q Standard value: 2.8 to 3.2 MPa
{28 to 32 kg/cm2}
WA1200-6 30-95
Hydraulic system
Testing and adjusting PV control relief valve oil pressure
Adjusting 30-96
a If the oil pressure is not within the standard value
range, adjust the PV control relief valve within
the standard value.
q Loosen lock nut (4) of the PV control valve and
ment screw:
Per turn: 1.0 MPa {10.4 kg/cm2}
3 Locknut:
29.4 to 39.2 Nm {3 to 4 kgm}
30-96 WA1200-6
Hydraulic system
Testing and adjusting differential valve output oil pressure
Testing and adjusting differential valve output oil pressure 30-97

a Testing tools a Measure the oil pressure from A port of NC
Symbol Part No. Part name valve (3) to P1 port of ES valve (1) and the oil
Oil pressure gauge kit (analog) pressure from PB port of differential valve (4)
799-101-5002 (Pressure gauge: 6 MPa to P2 port of ES valve (1). Obtain and check
1
C {60 kg/cm2}) the difference in pressure between P1 and
790-261-1204 Oil pressure gauge kit (digital) P2 ports.
2 799-101-5160 q Nipple
4 799-261-1311 q Adapter

from moving.
Testing 30-97
q Differential valve output oil pressure can be 1. Stop the engine.
checked by measuring the input pressure at P1 k Operate the work equipment control lever
and P2 ports of the ES valve. to release the pressure from the work
a ES valve (1) is installed to No. 2 work equip- equipment PPC accumulator.
ment pump (2). 2. Disconnect hose (5) from P1 port and hose (6)
from P2 port of the ES valve. Install adapters C4
and nipples C2 and reconnect hoses (5) and (6).
WA1200-6 30-97
Hydraulic system
Testing and adjusting differential valve output oil pressure
3. Install oil pressure gauge C1 (6 MPa Adjusting 30-98

{60 kg/cm2}) to nipple C2. 1. If the pressure difference is out of the standard
value, replace the differential valve or follow the
steps below to bring it in line with the standard
value by adjusting the valve.
1) Stop the engine.
k Operate the work equipment control
lever to release the pressure from the
work equipment PPC accumulator.
2) Remove differential valve assembly (4).

a Clean any oil, dirt, etc. off the valve and
piping.
Reference
Operating conditions for NC valve (to reduce
piston pump delivery)
q Gear speed: F3
q Travel speed: Min. 10 km/h
q Work equipment control levers: Neutral
4. Measure oil pressure at P1 and P2 ports with the

engine running at low idle (650 rpm) and at high
idle (1,900 rpm). Check whether the differences
in pressure between Port 1 and Port 2 meet the
standard values. 3) Remove plug (7), and add or remove shims
(8).
q Standard values for pressure difference be- a When adjusting by using shims for the dif-
tween P1 and P2 ports ferential valve, set it with the plug facing
Oil pressure (MPa Differential up.
{kg/cm2}) pressure a Shim part No.: 427 - 62 - 11710 (t 0.1)
Engine speed (MPa : 427 - 62 - 11720 (t 0.2)
P1 port P2 port : 427 - 62 - 11730 (t 0.5)
{kg/cm2})
Low idle 3.7 to 3.9 3.7 to 3.9 a The set pressure will increase by adding
0
(625 – 675 rpm) {38 to 40} {38 to 40} shims, and decrease by removing shims.
High idle 4.9 to 5.5 4.3 to 4.9 0.5 to 0.6
(1,850 – 1,950 rpm) {50 to 56} {44 to 50} {5 to 6}
4) Install plug (7) and then install differential

valve assembly (4).
30-98 WA1200-6
Hydraulic system
Testing work pump ES valve output pressure
Testing work pump ES valve output pressure 30-9

a Testing tools a Oil pressure enters the ES valve from the work
Symbol Part No. Part name equipment pump cut-off solenoid valve (3) port A
Oil pressure gauge kit (analog) to ES valve (1) port P1, and from differential
799-101-5002 (pressure gauge: 6 MPa pressure valve (4) port PB to ES valve (1) port
1
C {60 kg/cm2}) P2. The output pressure of the ES valve is deter-
790-261-1204 Oil pressure gauge kit (digital) mined by the differential pressure between port
2 799-101-5160 q Nipple P1 and port P2.
4 799-261-1311 q Adapter

from moving.
a Work equipment pump ES valve (1) is installed

to No. 2 work equipment pump (2).
WA1200-6 30-99
Hydraulic system
Testing work pump ES valve output pressure
Testing 30-10 q ES valve output pressure standard value: 1.8

a Install pressure gauges to ports P1 and P2 of the MPa {18.34 kg/cm2}
ES valve to measure the differential pressure,
referring to "Testing and adjusting differential
valve output oil pressure".
1. Stop the engine.

k Operate the work equipment control lever
to release the pressure from the work
equipment PPC accumulator.
2. Disconnect hose (5) from the ES valve output
port, install adapter C4 and nipple C2 to tee (6),
and connect hose (5) again.
3. Connect oil pressure gauge C1 (6 MPa
4. Run the engine at high idle (2,050 rpm), slowly

tilt the bucket, and check if the ES valve output
pressure is 1.8 MPa {18.34 kg/cm2} as the stan-
dard value when the differential pressure
between port P1 and port P2 (P1-P2) is 0.33
MPa {3.35 kg/cm2} by reading oil pressure
gauge C1.
30-100 WA1200-6
Hydraulic system
Testing and adjusting work pump CO (cut-off) valve oil pressure
Testing and adjusting work pump CO (cut-off) valve oil pressure 30-101
a Testing tools No. 1 work equipment pump 30-101
Symbol Part No. Part name 1. Preparation
Oil pressure gauge kit (analog) 1) Remove the rear side pump delivery pres-
799-101-5002 (Pressure gauge: 40 MPa sure pickup plug (7) on the No. 1 work equip-
1
{400 kg/cm2}) ment pump.
C 790-261-1204 Oil pressure gauge kit (digital) 2) Install joint C3 and nipple C2 of the oil pres-
2 799-101-5160 q Nipple sure gauge kit, and connect oil pressure
3 790-301-1271 q Joint
4 790-261-1311 q Adapter gauge C1 (40 MPa {400 kg/cm2}) to nipple
C2.
from moving.
a Obtain the oil pressures of the work equipment

pump CO valves by measuring, at ports on the
servo valve side, the delivery pressures of No. 1 3) Remove step (1) from No. 1 work equipment
work equipment pump (1) and No. 2 work equip- pump (1).
ment pump (2) and the output pressures of CO
valve (4) on the No. 1 work equipment pump and
CO valve (5) on the No. 2 work equipment pump.
WA1200-6 30-101
Hydraulic system
4) Remove CO+NC valve output pressure port

plug (9) from rear side servo valve (8) of No.
1 work equipment pump (1).
5) Install joint C3 and nipple C2 of the oil pres-
sure gauge kit, and connect oil pressure
gauge C1 (6 MPa {60 kg/cm2}) to nipple C2.
3) Turn in the screw until the CO valve output

pressure reading on gauge (B) agrees with
the standard value when the reading on
gauge (A) reaches 27.5 MPa {280 kg/cm2}
as the lift arm lever on the work equipment is
slowly moved to RAISE to increase the No. 1
work equipment pump delivery pressure.
q CO valve output pressure standard value:
0.37 MPa {3.8 kg/cm2}

a Increase the engine speed if the No.1
work equipment pump delivery pressure
does not reach 27.5 MPa {280 kg/cm2}.
2. Testing CO valve oil pressure

1) Adjust by loosening lock nut (10) for CO+NC
valve (4) and turning adjustment screw (11)
with a screwdriver.
2) With the engine running at low idle (650 rpm)
and the bucket slowly brought to TILT end,
read the No.1 work equipment pump delivery
pressure and the CO valve output pressure
on oil pressure gauges (A) and (B).
A: Pump delivery pressure gauge
C1 (40 MPa {400 kg/cm2})
B: CO valve output pressure gauge
C1 (6 MPa {60 kg/cm2})
30-102 WA1200-6
Hydraulic system
3. Adjusting CO valve pressure No. 2 work equipment pump 30-103

1) Adjust by loosening lock nut (10) for CO+NC 1. Preparation
valve (4) and turning adjustment screw (11) 1) Remove front pump delivery pressure pickup
with a screwdriver. plug (11) from the No. 2 pump.
a To raise the cut-off, turn adjustment 2) Install joint C3 and nipple C2 of the oil pres-
screw (11) clockwise. To lower the sure gauge kit, and connect oil pressure
cut-off, turn it counterclockwise. Repeat gauge C1(40 MPa {400 kg/cm2}) to nipple
the procedure until the correct set pres- C2.
sure is obtained.
a Turning in the adjustment screw one turn
will increase the No. 1 work equipment
pump delivery pressure by 4.1 MPa
{41.3 kg/cm2}.
3) Disconnect hose (14) from elbow (15) on

front servo valve (13) of the No. 2 pump.
4) Install adapter C4 and nipple C2 of the oil
pressure gauge kit to elbow (15) and connect
hose (14).
5) Install oil pressure gauge C1 (6 MPa
2) After adjustment is completed, remove the

joint and nipple of the oil pressure gauge kit
and restore the machine.
WA1200-6 30-103
Hydraulic system
2. Testing CO valve oil pressure 3. Adjusting CO valve pressure

1) With the engine running at low idle (650 rpm) 1) Adjust by loosening lock nut (16) for CO+NC
and the bucket slowly brought to TILT end, valve (5) and turning adjustment screw (17)
read the No.2 work equipment pump delivery with a screwdriver.
pressure and the CO valve output pressure a To raise the cut-off, turn adjustment
on oil pressure gauges (A) and (B). screw (17) clockwise. To lower the
A: Pump delivery pressure gauge cut-off, turn it counterclockwise. Repeat
C1(40 MPa {400 kg/cm2}) the procedure until the correct set pres-
B: CO valve output pressure gauge sure is obtained.
C1(6 MPa {60 kg/cm2})
{41.3 kg/cm2}.
2) Check to ensure that the CO valve output

pressure reading on gauge (B) agrees with
the standard value when the reading on
gauge (A) reaches 25.5 MPa {260 kg/cm2}
as the bucket lever on the work equipment is
slowly moved to TILT to increase the No. 2
work equipment pump delivery pressure.
0.74 MPa {7.6 kg/cm2}

a Increase the engine speed if the No. 2

joint adapter and nipple of the oil pressure
gauge kit and restore the machine.
30-104 WA1200-6
Hydraulic system
Testing and adjusting work equipment pump TVC valve oil pressure
Testing and adjusting work equipment pump TVC valve oil pressure 30-105
a Testing and adjusting tools for No. 2 work 2) While running the engine at low idle (650
equipment pump rpm), gradually move the pallet to tilt end and
Symbol Part No. Part name measure the TVC valve output pressure.
1
799-101-5002 Hydraulic tester 3) Install nipple N3 and connect it to oil pressure
790-261-1204 Digital hydraulic tester gauge [1] of hydraulic tester N1.
2 799-401-2701 Differential pressure gauge a Use an oil pressure gauge with the ca-
N
799-101-5220 Nipple (10 x 1.5 mm)
3
07002-11023 O-ring pacity of 6 MPa {60 kg/cm2}.
4 799-401-3200 Adapter (size: 03)

from moving.
1. Measuring TVC valve output pressure 4) Gradually operate the lift arm lever of the
a Since the TVC valve output pressure varies work equipment and let the No. 2 work equip-
with the delivery pressure of the pump, check ment pump delivery pressure increase.
that the oil pressure in the work equipment Measure the TVC valve output pressure.
circuit is normal before starting measure- 5) After completing measurement, remove the
ment. measuring instruments and restore the
a Since the source pressure of the TVC valve machine.
output pressure is the control circuit pres-
sure, check that the control circuit pressure is 2. Adjusting TVC valve
normal before starting measurement. a If the TVC valve output pressure is abnormal,
1) Remove oil pressure pickup plug (1) of the adjust TVC valve (8) of the No. 2 work equip-
No. 2 work equipment pump. ment pump according to the following proce-
dure.
WA1200-6 30-105
Hydraulic system
Testing and adjusting work equipment pump TVC valve oil pressure
1) While fixing adjustment screw (9), loosen

lock nut (10).
2) Turn adjustment screw (9) to adjust oil pres-
sure.
creased.
sure is decreased.
0.34 MPa {3.5 kg/cm2}
3) While fixing adjustment screw (9), tighten
lock nut (10).
3 Locknut:
5.9 to 9.8 Nm {0.6 to 1.0 kgm}
4) After completing adjustment, check the oil

pressure again according to the above
measurement procedure.
30-106 WA1200-6
Hydraulic system
Operation test of work equipment valve by work equipment speed (speed of work equipment is low)
Operation test of work equipment valve by work equipment speed

(speed of work equipment is low) 30-107
a Testing tools Testing 30-107
Sym- 1. Operate each individual work equipment valve to
Part No. Part name
bol raise the boom, measure the time it takes for the
Oil pressure gauge kit (analog) boom to raise and determine whether the time is
(Pressure gauge: 6 MPa correct or too slow.
799-101-5002
1 {60 kg/cm2}), 40 MPa 2. If the rising time is too slow, the corresponding
{400 kg/cm2} valve is faulty (inoperative) or the hydraulic
790-261-1204 Oil pressure gauge kit (digital) pump is faulty.
C 2 799-101-5160 q Nipple
3 790-301-1271 q Joint
4 790-261-1311 q Adapter
9 07376-50315 q Plug (on PPC hose)
q Sleeve nut (central block
10 07221-20315
side)
11 07222-00312 q Plug (central block side)

a If slow work equipment speed or other problems
occur that appear attributable to the work equip-
ment hydraulic system but it is not possible to
determine which device(s) is the cause(s), trou-
bleshoot by following the steps below.
WA1200-6 30-107
Hydraulic system
3. Symptoms and rising times for individual work equipment valves

q Boom rising time (ground o max. RAISE) (bucket empty)
1) Engine at height idle (1,850 – 1,950 rpm) Q: Valve operated -: Valve not operated
Rising time too slow
Valve No. When normal
Condition 1 Condition 2 Condition 3
No. 1 (left) Q Q – –
No. 2 (center) Q – – Q
No. 3 (right) Q – Q –
Time (sec) 12 – 14 41 – 44 33 – 35 41 – 44
2) Engine at low idle (625 – 675 rpm) Q: Valve operated -: Valve not operated
Rising time too slow
Valve No. When normal
Condition 1 Condition 2 Condition 3
Time (sec) 36 – 39 205 – 208 58 – 61 205 – 208
4. Individual valve delivery (reference)
1) Max. pump swash plate angle Q: Valve operated -: Valve not operated
Valve No. When normal Condition 1 Condition 2 Condition 3
Delivery (l/min) 1,694 522 650 522
2) Min. pump swash plate angle Q: Valve operated -: Valve not operated
Valve No. When normal Condition 1 Condition 2 Condition 3
Delivery (l/min) 584 107 370 107
5. Pump deliveries and individual valve filtering oil flow (reference)
1) Max. pump swash plate angle
No. 1 work equipment pump No. 2 work equipment pump Switching pump Delivery
Valve No.
Front (F) Rear (R) Front (F) Rear (R) Front (F) Rear (R) (l/min)
No. 1 (left) – 325 197 – – – 522
No. 2 (center) 325 – – 197 – – 522
No. 3 (right) – – – – 325 325 650
a The side of the pump to which PTO is connected is called front pump (F) and the opposite side rear
pump (R).
2) Min. pump swash plate angle
No. 1 work equipment pump No. 2 work equipment pump Switching pump Delivery
Valve No.
Front (F) Rear (R) Front (F) Rear (R) Front (F) Rear (R) (l/min)
No. 1 (left) – 45 62 – – – 107
No. 2 (center) 45 – – 62 – – 107
No. 3 (right) – – – – 45 325 370
3) Boom cylinder swept volume

Stroke Swept volume
(mm) (2 cylinders)(l)
1,812 368.9
30-108 WA1200-6
Hydraulic system
Check 30-109 No. 1 valve (boom spool)

a If the work equipment speed is too low, the faulty q Disconnect PPC hoses (3) and (4) from blocks
(inoperative) valve can be identified by operating (1) and (2). Correctly install plug C9, sleeve nut
that valve to measure the boom rising time while C10 and plug C11 to the blocks and PPC hoses.
closing the boom PPC pilot ports (both for lower-
ing and raising) for all other valves to prevent the No. 2 valve (boom spool)
relevant boom spools from being actuated. q Disconnect PPC hoses (5) and (6) from blocks
a There is a valve on which the main relief valve (1) and (2). Correctly install plug C9, sleeve nut
pressure is not set to the standard value. C10 and plug C11 to the blocks and PPC hoses.
q Main relief valve operating pressure:
31.4 MPa {320 kg/cm2} No. 3 valve (boom spool)

1) With the circuits (for both tilting and dumping) q Disconnect PPC hoses (7) and (8) from blocks
closed other than the one for the bucket pilot (1) and (2). Correctly install plug C9, sleeve nut
circuit on one of the No. 1, No. 2 and No. 3 C10 and plug C11 to the blocks and PPC hoses.
valves, tilt the bucket while noting the pres-
sure at which the relief valve is actuated. No. 1 valve (bucket spool)
a Check the relief valve operating pressure in q Disconnect PPC hoses (9) and (10) from blocks
"Testing and adjusting work equipment oil (1) and (2). Correctly install plug C9, sleeve nut
pressure". C10 and plug C11 to the blocks and PPC hoses.
a If the relief valve set pressure reading agrees
with the standard value, the valve with the No. 2 valve (bucket spool)
closed circuits is incorrectly adjusted. q Disconnect PPC hoses (11) and (12) from the
k Park the machine on a level ground, apply blocks (1) and (2). Correctly install plug C9,
the parking brake, lower the bucket to the sleeve nut C10 and plug C11 to the blocks and
ground, and reserve a safe area. PPC hoses.
from moving. No. 3 valve (bucket spool)
k Operate the work equipment control lever q Disconnect PPC hose (15) from nipple (14) on
two to three times to release pressure from tube (13).
the PPC accumulator circuit. q Disconnect PPC hose (16) from block (2).
q Correctly install plug C9, sleeve nut C10 and
plug C11 to the nipple, block and PPC hose.
a With the PPC hose correctly disconnected, start
the engine.
a After testing and adjusting, restore the PPC
hose to the original position as it was before.
WA1200-6 30-109
Hydraulic system
30-110 WA1200-6
Hydraulic system
Schematic of valves and pilot lines 30-1 1
WA1200-6 30-111
Hydraulic system
[Reference] PPC output circuit
30-112 WA1200-6
Hydraulic system
WA1200-6 30-113
Hydraulic system
Testing hydraulic oil cooler performance
Testing hydraulic oil cooler performance 30-1 4

(Testing by temperature difference) 30-1 4
Testing condition 30-1 4
Engine speed: High idle
Coolant temperature: Within operating range
Hydraulic oil temperature: 60 °C
a To test the hydraulic oil cooler performance,
measure the temperature of inlet and outlet
tubes with a temperature gun and calculate the
difference.
q Aim a temperature gun to inlet tube (4) and outlet

tube (5) to measure the temperature and calcu-
late the difference.
a Temperature difference standard value: 11 to
13 °C
30-114 WA1200-6
Hydraulic system
(Testing by oil pressure measurement) 30-1 5

a Testing tools
B 799-101-1502 Digital thermometer kit
799-101-5002 (pressure gauge: 2.5 MPa
1
C {25 kg/cm2})
3 790-301-1271 q Joint
1. In order to test the hydraulic oil cooler outlet
pressure, drill and tap oil pressure pickup holes
(10 mm dia., thread pitch 1.25 mm) at position
"B" of tubes (1) and (2) in the drawing.
a Part number of plug installed to tapped hole:
07040-11007: Plug
07002-21023: O-ring
2. Measure the hydraulic oil cooler outlet oil

temperature, oil pressure, and engine speed.
1) Temperature difference between hydraulic
oil cooler inlet and outlet
q Temperature difference standard value:
11 to 13 °C
2) Referring to the hydraulic oil cooler oil pres-
sure and oil temperature characteristics,
judge the good/bad of the cold relief valve.
WA1200-6 30-115
Hydraulic system
Hydraulic oil cooler oil pressure and oil temperature characteristics 30-1 6
Hydraulic oil Hydraulic oil
Flow (refer-
cooler cooler oil tem- Engine speed Remarks
ence)
inlet pressure perature
0.26–0.30 MPa Low idle
40 °C 380 l <Reference>
{2.6–3.0 kg/cm2} (650 rpm)
Cold relief valve set pressure:
Normal
0.30–0.34 MPa At rated speed

40 °C 560 l 0.5 MPa {5.1 kg/cm2}
{3.0–3.4 kg/cm2} (1,900 rpm)
Surge cut valve set pressure:
0.34–0.38 MPa High idle
40 °C 713 l 0.5 MPa {5.1 kg/cm2}
{3.4–3.8 kg/cm2} (2,050 rpm)
0.15 MPa Low idle
40 °C 380 l Cold relief valve set pressure is too low
{1.5 kg/cm2} (650 rpm)
Abnormality
0.69 MPa High idle

40 °C 700 l Cold relief valve set pressure is too high
{7.0 kg/cm2} (2,050 rpm)
0.29 MPa q Clogging inside hydraulic oil cooler
High idle
100 °C 713 l q Cold relief valve set pressure is too low
{3.0 kg/cm2} (2,050 rpm)
q Steering pump flow is too low
30-116 WA1200-6
Hydraulic system
Bleeding air from hydraulic circuit
Bleeding air from hydraulic circuit 30-1 7

Bleeding air from wheel brake circuit 30-1 7
a If a brake circuit hose has been disconnected for
removal of the brake valve or axle, bleed air from
the circuit according to the following procedures.
k Apply the parking brake and chock the
wheels to prevent the machine from moving.
k Never bleed air from the slack adjuster while
the engine is running during which the pro-
peller shaft is rotating.
1. Start the engine and accumulate pressure in the

accumulator.
(To be completed in about 30 seconds at high
idle)
2. With the engine started, insert one end of the
vinyl hose in the bleeder (1) and place the other
end in a container.
3. Depress the brake pedal and then loosen
bleeder screw to remove air. Return the brake
pedal slowly after tightening the bleeder screw.
a This work must be performed by two workers.
One worker depresses the brake pedal and
the other removes air through the bleeder
screw.
a Use the L.H. brake pedal.
a Keep the brake oil full at all times by adding it
as necessary.
4. Repeat these steps and, when oil clear of air
bubbles flows out of vinyl hose, depress the
pedal fully and tighten the bleeder screw while
the oil is flowing out.
5. Using the same procedures, perform the same
steps for the slack adjuster on the opposite side
and the bleeder (1) of each wheel.
a If the pressure in the accumulator drops, start
the engine to charge the accumulator.
a After the air bleeding procedure, let the en-
gine run at low idle and check the brake oil
tank for oil level. Add oil as necessary.
a After the air bleeding procedure, make the
"Testing brake performance".
WA1200-6 30-117
Hydraulic system
Bleeding air from brake pump circuit 30-1 8

a When the brake oil, brake line, or brake pump 4. Start the engine and show the brake oil pressure
has been replaced with new one, perform the fol- of Pm Clinic on the KOMTRAX Plus screen.
lowing air bleeding procedure. 5. Let the engine run for five minutes. When the
1. Check that the oil level of the brake tank is high brake oil pressure is normal, return the R3 main
level. relief valve (3) of the accumulator charge valve
2. Bleed air from the wheel brake circuit referring to to its original position and tighten the lock nut (2).
"Bleeding air from wheel brake circuit" section. 6. Check the oil level of the brake oil tank again and
3. Loosen the lock nut (2) of the R3 main relief add oil as necessary.
valve of the accumulator charge valve (1) and 7. Depress the foot brake and make sure that the
return the main relief valve (3) until only a brake circuit operates correctly and the brake
minimal amount of pressure is applied to the charge cut in/out pressures are normal.
valve spring.
a Mark the positions of the lock nut (2) of the
R3 main relief valve and the main relief valve
(3) with a marker pen so that they can be re-
turned to their respective original positions.
30-118 WA1200-6
Hydraulic system
Bleeding air from piston pump 30-1 9

a When oil of the hydraulic tank or the piston pump
has been replaced with a new one, or the piston 2. Bleeding air from piston pump
pump pipe has been replaced, bleed air from the 1) Loosen the air bleeder plug (1) on the upper
circuit by following the procedure given below to surface of the tube on the piston pump
prevent pump seizure. suction side, the plugs (3) and (4) on the
1. Preparation upper surface of the steering pump and the
Add oil to the H level of the tank level gauge (1). switch pump, and the fittings of the hose (2)
(Type of oil: SAE 10WCD or H046-HM) connecting the work equipment pumps 1 and
2.
2) When oil overflows from the plug, indicating
that the pump has been completely bled of
air, tighten the plugs and hose fittings.
3) Wipe any spilled oil and add oil up to H level
of the tank.
WA1200-6 30-119
Hydraulic system
Bleeding air from the oil filter of the hydraulic Bleeding air from work equipment circuit 30-120
tank 30-120 a When the hydraulic oil control valve or work
a If the oil in the hydraulic tank, piston pump, con- equipment cylinder has been removed and rein-
trol valve, or the hydraulic cylinder has been re- stalled, bleed the system of air by following the
placed with a new one, bleed air from the oil filter procedure given below.
of the hydraulic tank by following the procedure 1. Add oil to the hydraulic tank until the oil level
given below. reaches the window in the sight gauge (1).
1. Check that the hydraulic oil is full up to the

window in the hydraulic tank sight gauge (1).
2. Add oil 400 l further.
3. Tighten cap (5).

2. Loosen air bleeder plugs (1), (2), (3), and (4) at
the upper portion of the filter.
4. Start the engine and run at low idle for five

minutes.
3. Start the engine and set its speed to low idle. Check for oil leaks.
a (Caution) Do not run the engine at high idle.
4. With oil overflowing from plugs (1), (2), (3), and Do not operate the cylinder to its stroke end
(4), indicating that the filter has been completely before bleeding air (the cylinder may break).
bled of air, tighten the plugs (1), (2), (3), and (4).
30-120 WA1200-6
Hydraulic system
5. Run the engine at low idle. 8. Run the engine at 1,500 rpm and slowly move
1) Slowly move the lift arm and bucket cylinder the lift arm and bucket cylinders to the stroke
just before the stroke end. end.
q Never let the relief valves actuate. q Never let the relief valves actuate.
q Raise and lower the lift arm and tilt and q Raise and lower the lift arm and tilt and dump
dump the bucket four to five times repeat- the bucket four to five times repeatedly.
edly.
2) Slowly move the lift arm and bucket cylinders air. (see No. 6)
up to the stroke end.
q Never let the relief valves actuate. 10. Repeat No. 8 and No. 9 until the air is completely
q Raise and lower the lift arm and tilt and bled.
dump the bucket four to five times repeat-
edly. 11. When the air is completely bled, check the oil
6. Stop the engine and loosen plugs (1) to (4). reaches the Full mark in the sight gauge.
Then, bleed air from the hydraulic oil filter case.
1) Loosen plugs (1) to (4) slowly to bleed air
from the case one at a time.
and replace any damaged plugs with new
ones.

level. Then, add oil up to the window in the sight
gauge (1).
WA1200-6 30-121
Hydraulic system
Releasing remaining pressure in hydraulic circuit
Releasing remaining pressure in hydraulic circuit 30-12

Releasing remaining pressure between each hy-

draulic cylinder and control valve 30-12
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
1. Stop the engine.
2. Loosen the oil filler cap gradually to release the

pressure inside the tank.
3. Operate the control levers.

a When the levers are operated two to three
times, the pressure stored in the accumulator
is removed.
4. Start the engine, run at low idle for approximately

5 seconds, stop the engine, and then operate the
control levers.
a Repeat above steps 4) and 3) two to three
times to remove the remaining pressure
completely.
Releasing remaining pressure in brake accumu-

lator circuit 30-12
a When disconnecting the piping between the ac-
cumulator and accumulator check valve, or the
piping between the accumulator and brake
valve, remove the remaining pressure in the cir-
cuit according to the following procedures.
1. Stop the engine.
2. Depress the brake pedal 100 times or more to

release the pressure in the brake accumulator
circuit.
Releasing remaining pressure in PPC accumula-

tor circuit 30-12
a If the piping between the PPC accumulator and
PPC valve is to be disconnected, release the re-
maining pressure from the circuit as follows.
a Operate the control lever two to three times to re-
lease all the remaining pressure from the circuit.
30-122 WA1200-6
Work equipment
Checking center hinge pin lubrication

Checking center hinge pin lubrication 30-123
k Be sure to follow "Safety precautions to fol- a If fresh grease is not oozing out from bearing
low before starting work". end surfaces (a) and (b), fill grease until fresh
k Park the machine on a flat and firm ground. grease comes out.
k Lower the bucket to the ground and apply the
parking brake.
from moving.
Checking 30-123
q To prevent damage to the center hinge portion
bearings due to insufficient lubrication by the au-
to-greasing system, check for the following.
1. Check the lubrication condition at the center
hinge part (upper (1) and lower (2)). If fresh
grease is not oozing out, manually fill grease
using a grease gun.
2. Make sure that genuine grease is always used in
the grease pump.
a Check the lubrication condition of the upper

center and lower center hinge portions by the
grease oozing out from the bearing end sur-
faces (a) and (b).
WA1200-6 30-123
Work equipment
Checking center hinge pin lubrication
a When filling grease manually, use the injec-

tors marked by asterisks (*) in the drawing
below (two places).
30-124 WA1200-6
Work equipment
Adjustment method of auto grease injector delivery
Adjustment method of auto grease injector delivery 30-125

1. The injector operates by the pressure from the
pump, and feeds a preset amount of grease to
the bearing.
2. To check if the injector is operating normally,

observe the movement of indicator pin (1) at the
head. When normal, the pin retracts first, and it
returns to the original position after the pump
stops and the pressure is released. The pin is
reset for the next time of greasing.
3. Delivery of the injector is adjusted by turning
adjustment screw (3) at the head.
1) To decrease the delivery, loosen lock nut (2)
and turn adjustment screw (3) clockwise. The
delivery becomes minimum when the screw
bottoms (comes in contact with the stopper).
2) The delivery becomes maximum when the
screw is backed off from the
above-mentioned bottomed (minimum
delivery) position by 10 turns. Maximum
delivery (1.3 cc/ST)
a After adjusting the injector delivery as shown

above, be sure to tighten lock nut (2).
4. The injector can be overhauled or replaced,

however, it is recommended to replace a faulty
injector with a replacement assembly.
q Loosen lock nut (2) and turn adjustment
screw (3) to adjust the delivery of grease per
injection.
Delivery per injection

Screw-in clockwise until bottoms
0.13 cc (Min.)
against stopper
Back-off counterclockwise 10
1.30 cc (Max.)
turns from above position
q Between max. and min. positions, delivery

changes by 0.13 cc per turn of screw.
a After adjusting the screw, be sure to tighten
the lock nut.
WA1200-6 30-125
Work equipment
Setting method of auto grease timer
Setting method of auto grease timer 30-126

k After adjustment, correctly close the lid on 2. Adjusting interval time (blue dial)
the timer box to prevent water ingress. Open the bottom door at the rear of the cab.
Open the lid of the timer box. Turn the blue dial
q The timer is provided to control greasing inter- illustrated on the right to adjust interval and oper-
vals of the auto grease system. ating times.
q The timer is installed in box (1) behind the oper- To adjust interval time, turn the blue rotary
ator seat. switch (1) illustrated on the right in accordance
q Greasing intervals can be changed as needed in with the table on the next page.
accordance with the table below by adjusting the
blue dial on the timer. It has an error of about
±15%. (both pause and in operation)
Example: Set to 11.25 minute

11.25 11.25 11.25
min. min. min.
pause pause pause
I I
Run-
ning
1. Adjusting greasing intervals

The timer box (1) is located as illustrated on the
right.
q Timer power
Even after the starting switch is turned to
OFF, the capacitor (Super Cap) on this circuit
board ensures that interval time and oper-
ating time are both retained in the memory for
about 5 days and that the next time the
system starts where it stopped at the
previous power shutoff. If power is away for
more than 5 days, the data in the memory will
be lost.
30-126 WA1200-6
Work equipment
Setting method of auto grease timer
Position of switch 1 2 3 4 5 6 7 8 9
Greasing interval (min.) 3.75 7.5 11.25 15 18.75 22.5 28.25 30 33.75
Position of switch A B C D E F
Greasing interval (min.) 37.5 41.25 45 48.75 52.5 56.25
q Upon installing the auto grease system, set

the blue dial to "3".
3. Adjusting operating time (red dial)

To adjust operating time, turn the red rotary
switch (1) illustrated on the right in accordance
with the table below. (Normally, leave the switch
in "2" (15 second).)
Position of switch 1 2 3 4 5 6 7 8 9
Greasing interval (sec.) 7.5 15 22.5 30 37.5 45 58.5 60 67.5
Position of switch A B C D E F
Greasing interval (sec.) 75 82.5 90 97.5 105 112.5
1) Set the red dial to "2". (under normal oper-
ating condition)
2) The grease pump stops when it is balanced
upon completion of greasing even if this
happens before the set pump operating time
(15 second) passes.
WA1200-6 30-127
Electrical system
Testing and adjusting bucket proximity switch

Testing and adjusting bucket proximity switch 30-128

low before starting work". 4. Since angle (2) moves laterally in relation to the
sensing surface of the switch, adjustment should
Checking 30-128 be made so that clearance a is 3 to 5 mm along
1. Start the engine and operate the bucket to acti- the entire length of the angle that passes the
vate proximity switch (1). Stop the engine and front of the switch.
measure clearance a between the proximity
switch and angle (2).
a Standard clearance: a = 3 to 5 mm
5. Adjust the proximity switch mounting bracket (5)

so that the bucket angle becomes 0 to 1 deg.
downward when the engine is running at around
2. Run the engine at around 1,500 rpm, let the 1,500 rpm, positioner activated, and the bucket
proximity switch activate, and lower the bucket lowered to the ground.
to the ground. Check if the bucket angle is 0 to a The nominal position of the bracket is c=139
1 deg. downward. mm on a standard set.
Adjusting 30-128
1. If clearance a is out of the standard value, adjust
it according to the following procedure.
2. Lower the bucket to a level ground.
3. Adjust proximity switch (1) so that clearance b
between the sensing surface of proximity switch
(1) and the end of protector (3) falls within the
standard value range, and then tighten nut (4) to
secure in position.
q Standard clearance: b = 0.5 to 1.0 mm
3 Nut:
14.7 to 19.6 Nm {1.5 to 2.0 kgm}
a The relation between the bucket angle and

cylinder length at around ground level is 12
mm/1 deg.
6. The variation of angle during bucket operation

due to different engine speeds is within 4 deg.
when the bucket is at near ground level.
a If adjustment is not accomplished, repeat
steps 1 to 4 again.
30-128 WA1200-6
Electrical system
Adjusting lift arm potentiometer
Adjusting lift arm potentiometer 30-129

a Perform adjustment after the lift arm is installed.
1. Remove bolt (1) and cover (2).
2. Raise the lift arm to the maximum height at the

lift arm cylinder stroke end, and stop the engine.
3. Loosen two screws (3).
4. Connect a T-adapter between the front wiring

harness and the potentiometer, and turn the
starting switch to the ON position. Gradually turn
the potentiometer clockwise or counterclockwise
until the voltage between CN-F04 terminals (A)
and (B) becomes 4.3 ± 0.33 V.
5. After finishing the potentiometer adjustment,

temporarily tighten screw (3) and turn the
starting switch OFF and then ON again.
6. Start the engine, lower and raise the lift arm to

the maximum height, and then check again if the
voltage is as described in step 4.
a If the voltage is within the range specified in
step 4, finally tighten screw (3) and assemble
the cover (2) and bolt (1) as they were before.
a If the voltage is not within the range specified
in step 4, repeat the adjustment referring to
step 4.
a Potentiometer standard values

Maximum lift arm angle 4.33 ± 0.33 V
Minimum lift arm angle 0.66 ± 0.33 V
WA1200-6 30-129
Electrical system
Adjusting lift arm levelness detecting switch
Adjusting lift arm levelness detecting switch 30-130
k Be sure to follow "Safety precautions to fol- 6. Adjust at the oblong hole in bracket (4) so that
low before starting work". cover (2) overlaps with half of the sensitive
a Lateral adjustment surface of proximity switch (1).
a See Fig. Y
1. Lower the bucket to a level ground.
2. Adjust proximity switch (1) so that clearance d

between the sensing surface of proximity switch
(1) and cover (2) falls within the standard value
range, and then tighten nut (3) to secure in posi-
tion.
a Standard clearance: d=3 to 5 mm
3 Nut:
14.7 to 19.6 Nm {1.5 to 2.0 kgm}
7. After adjusting, tighten bolts (5).
3. Since cover (2) passes the sensing surface of

the switch, adjustment should be made so that
clearance d is within the standard range along
the entire length of the cover that passes the
front of the switch.
a Adjusting lift arm in rotation direction
4. Set the lift arm to a horizontal position.
5. Loosen the two switch mounting bracket bolts

(5).
30-130 WA1200-6
Electrical system
Initial setting procedure for remote boom positioner (origin input method)
Initial setting procedure for remote boom positioner (origin input

method) 30-131
a Perform this setting to accomplish "Adjusting lift 3. "Setting" is displayed, and when the automatic
arm potentiometer". correction calculation is finished,
1) "Setting Completed" is displayed. Press
1. Select "Service Menu"o"Adjustment switch "F1" to finish the setting.
Menu"o"Boom Angle Sensor Adjustment" on 2) If "Wrong Value" is displayed, perform the
the multi meter display screen and depress the setting again from step 2.
"F6" switch.
2. Follow the screen (Raise boom to upper limit

(stroke end) and press the Set button), and
press "F6".
WA1200-6 30-131
Electrical system
Checking proximity switch operation pilot lamp
Checking proximity switch operation pilot lamp 30-132
Proximity switch operation pilot lamp (Red)

q The proximity switch has a pilot lamp to indicate
its operating condition. Use this pilot lamp when
adjusting the proximity switch.
a Status of proximity switch operation pilot lamp

q When object of sensing is at (in vicinity of) the
sensing face of proximity switch: Lights up
q When object of sensing is apart from the sensing
face of proximity switch: Goes out
30-132 WA1200-6
Electrical system
Adjusting AJSS lever angle sensor and frame angle sensor
Adjusting AJSS lever angle sensor and frame angle sensor 30-13
k Be sure to follow "Safety precautions to fol- 3. In this condition, measure the voltage at frame
low before starting work". angle potentiometer (2) and lever angle potenti-
ometer (4).
Adjusting 30-13 a Voltage when potentiometer is in neutral po-
1. Move the frame lock bar to the "LOCK" position sition: 2.5 ± 0.3 V
and set the machine in the straight travel posi- 4. If the voltage is not 2.5 ± 0.3 V, loosen mounting
tion. screws (3) and (5) of potentiometers (2) and (4),
and then turn each potentiometer to adjust the
voltage.
a For the adjustment procedure, see"Adjusting

to the specified dimension.
a L Standard length: 342 mm
WA1200-6 30-133
Electrical system
Testing and adjusting potentiometer mounting position
Testing and adjusting potentiometer mounting position 30-134
k Be sure to follow "Safety precautions to fol- 2. Checking the frame angle potentiometer for
low before starting work". correct position
a The potentiometers can be checked for correct 1) With the engine started and set at low idle,
position on the multi monitor screen (See "Ad- move the steering lever fully to the right or
justing steering follow-up linkage"). left.
2) With the lever at the end of stroke, check the
Preparation work voltage between (3) and (10) of connector
a Before checking, ensure that all the related con- L05 (female) on the work equipment
nectors are properly inserted. controller. Alternatively, with the lever at the
a Keep the joystick steering lever in the NEUTRAL end of stroke, check the voltage between (1)
position unless it is used. and (3) of connector L30 (male) on the poten-
a Be sure to connect any disconnected connectors tiometer.
to the original configuration before going on to a Potentiometer voltage standard value
the next step. Item Standard value
a Connect a T-adapter and turn the starting switch Frame angle, right 0.5 to 1.5 V
to "ON".
Frame angle, left 3.5 to 4.5 V
Testing 30-134
1. Checking the steering lever potentiometer for
correct position
1) Move the steering lever fully to the right or
left.
2) With the lever at the end of stroke, check the
voltage between (10) and (9) of connector
L05 (female) on the work equipment
controller. Alternatively, with the lever at the
end of stroke, check the voltage between (A)
and (C) of connector S30 (male) on the
potentiometer.
a Potentiometer voltage standard value
Item Standard value
Steering lever angle, right 3.5 to 4.5 V
Steering lever angle, left 0.5 to 1.5 V
30-134 WA1200-6
Electrical system
Related electrical circuits 30-135
WA1200-6 30-135
Electrical system
Adjusting 30-136
a If the potentiometer position voltage is out of the 2. Adjusting the steering lever angle potentiometer
standard value, adjust following the steps below. 1) Loosen mounting screw (5) for steering lever
1. Adjusting the frame angle potentiometer angle potentiometer (4).
1) Check and ensure that length "L" of steering
follow-up linkage (1) agrees with the stan-
dard value.
a Specified length L: 342 mm
2) With the steering lever moved right or left to
the end of stroke, loosen mounting screw (3)
for frame angle potentiometer (2).
3) Turn the potentiometer until the voltage
reading comes to agree with the standard
value.
4) After completing adjustment, tighten potenti-
ometer mounting screw (3) and recheck the
potentiometer voltage.
2) With the steering lever moved right or left to

the end of stroke, check the voltage of poten-
tiometer (4).
3) Turn potentiometer (4) until the voltage
reading comes to agree with the standard
value.
4) After completing adjustment, tighten potenti-
ometer mounting screw (5) and recheck the
potentiometer voltage.
30-136 WA1200-6
Electrical system
Procedure for testing diodes
Procedure for testing diodes 30-137
q Test the single diode and the wiring harness with

built-in diode according to the following proce-
dure.
q Use a digital tester that has a diode testing
range.
1. Apply the red (+) probe of the tester to the anode
(P) side of the diode and apply the black (-)
probe to the cathode (N) side.
a The direction of continuity is marked on the
surface of the diode.
a When switched to the diode testing range, an
ordinary tester will indicate the voltage of the
internal battery, however, if this value:
q does not change o No continuity
q changes o Continuity (normal) (Note)
q is 0 or near 0 o Short circuit in diode
Note) In the case of a silicon diode, a value in the
range of 400 to 600 is indicated. Depending
on the type of tester, a value of 0.4 to 0.6 may
be displayed.
WA1200-6 30-137
Electrical system
Basic precautions for KOMTRAX Plus controller
Basic precautions for KOMTRAX Plus controller 30-138

1. Machine handling, safety, and maintenance To achieve the above function, a power
For safety precautions, operation, maintenance supply (continuous power supply) which is
of the machine, see the "Operation and Mainte- directly wired from the battery and to which
nance Manual" of the machine. power is constantly supplied from the battery,
in addition to the power supply (switch power
2. Handling the monitoring system supply) that is shut down when the "starting
Observe the following precautions for handling switch is turned OFF" or "engine is stopped".
of the monitoring system. The presence of the switched power supply
1) Disassemble, repair, or modify the machine and the continuous power supply identifies a
and system according to the manual. period during which data must be identified,
2) Do not touch the system while the machine is thereby allowing the data for that particular
operating. period to be stored in the internal memory.
3) Do not allow harnesses, connectors, or That is, KOMTRAX Plus uses the continuous
sensors to become caught; do not damage power supply to store the data accumulated
harnesses, connectors, or sensors by pulling during the period from "starting switch ON" to
them by force. Short circuits or disconnected "starting switch OFF" in the memory before
wires may cause failure or fire on the system letting the KOMTRAX Plus controller shut
or the machine itself. down the continuous power supply.
4) Take care to stick water, dust, or oil to the 2) Precautions for shutting down the contin-
system. uous power supply
Shut down the continuous power supply after
3. Continuous power supply (battery direct a lapse of three minutes (period of time
power supply) of the KOMTRAX Plus required to turn OFF the KOMTRAX Plus
1) Meaning and necessity of the continuous system, or the period of time required for data
power supply to be stored in memory) after "starting switch
KOMTRAX Plus has a function of deter- OFF".
mining and keeping a record of machine The accumulated data may be destroyed if
statuses for the period from "starting switch the system OFF time is shorter than three
ON" to "starting switch OFF", thus requiring a minutes.
different power supply from that for many The system OFF time varies depending on
other electronic devices and components. the size of stored data, rewriting frequency,
use time, and related factors.
1] Disconnecting the continuous power
supply from KOMTRAX Plus
Before disconnecting the continuous
power supply for repair work or other
reasons, first make sure that the monitor
display (7-segment LED shown below) of
the KOMTRAX Plus controller is OFF.
30-138 WA1200-6
Electrical system
2] Mounting a battery isolator or other power 4. Precautions for turning "ON" the KOMTRAX
shutoff device Plus power supply
1] Basic connections q The KOMTRAX Plus controller performs an
The basic applicable rule to go by is to initial check sequence (LED flashing off and
mount an engine stop switch that will on) for the first several tens of seconds after
not shut down the continuous power the power is turned "ON". Do not perform any
supply. of the following steps during this period.
2] If shutdown of all power is unavoid- q Operating the manual snap shot switch
able because of user's safety regula- q Downloading by PC
tions or other reason (Perform these steps after making sure
q Mount the battery isolator such that that the LED shows a total number in
the continuous power supply is shut sequence.)
down after holding it in the normal
state for at least three minutes after
the starting switch is turned OFF.
q If a timer or other timepiece is not
available, wait for three minutes or
more before shutting down the contin-
uous power supply.
q Accumulated data may be destroyed if
the retention time is shorter than
above.
WA1200-6 30-139
Electrical system
5. Precautions for replacing KOMTRAX Plus Replace the KOMTRAX Plus controller with a
and transmission controller new one with care not to subject the
1) Before starting the replacement proce- controller main body and harnesses to
dure excessive force or impact. Then, perform the
1] Downloading the KOMTRAX Plus data "initial setting" procedure by following the
Download the accumulated data before instructions given in the "analysis tool
replacing the KOMTRAX Plus controller instruction manual".
with a new one. Be careful that data accu-
mulated up to the point of replacement 6. Handling the communication (ORBCOMM)
will be lost by the replacement. controller
Next, send this accumulated data to the 1) The ORBCOMM controller needs an applica-
WebCARE. tion (for opening the communication line)
Download the data according to the before it can be used.
instructions given in the separate "Anal- k If the controller is turned ON before the
ysis tool instruction manual". application is properly processed, the
communication system fails due to un-
authorized data transmission.
Ask the operating administrator or
your Komatsu distributor for any que-
ry.
2) Turn ON the ORBCOMM power as the last
step (by connecting the connector).
After the checks of the KOMTRAX Plus
controller and other devices are completed,
connect the connectors (ORB-A, ORB-B) of
the ORBCOMM controller.
2] Shutting down the KOMTRAX Plus power

supply correctly
1] Shut down the normal power supply
through the "starting switch OFF"
procedure.
2] Hold the continuous power supply in
the normal state for at least three
minutes.
3] Shut down the continuous power
supply (battery direct).
2) Replacement procedure and action after

replacement
30-140 WA1200-6
Electrical system
7. Trend data items

Table 1: Trend analysis data
No. Item Content Unit Remarks
1 SMR SMR (ggenerated SMR) h
2 Calendar Calendar value (GMT) -
3 ENG. SPEED MAX Engine speed (max) rpm
4 ENG.SPEED AVE Engine speed (average) rpm
5 TM ENG.SPEED MAX Engine speed (max) (TM calculationvalue) rpm
Engine speed (average) (TM calculation-
6 TM ENG.SPEED AVE rpm
value)
7 BLOW-BY PRE.MAX Blow-by pressure (max) kPa
8 BOOST PR.MAX Boost pressure (max) kPa
9 ENG.OIL TMP.MAX Engine oil pressure (max) degC
10 COOL TEMP.MAX Engine coolant pressure( max) degC
11 COOL TEMP.MIN Engine coolant pressure (min) degC
12 E.OIL PRE.MAX Engine oil pressure (max) kPa
13 E.OIL P.L_MIN Engine oil pressure(low-idle) (min) kPa
14 E.OIL P.H_MIN Engine oil pressure (high-idle) (min) kPa
15 Exh.TEMP.LF MAX Exhaust temperature (L-1,2,3,4) (max) degC
16 Exh.TEMP.LR MAX Exhaust temperature (L-5,6,7,8) (max) degC
17 Exh.TEMP.RF MAX Exhaust temperature (R-1,2,3,4) (max) degC
18 Exh.TEMP.RR MAX Exhaust temperature (R-5,6,7,8) (max) degC
19 FUEL RATE Fuel consumption ratio (average) L/h
20 PPC PRES MAX PPC oil pressure (max) MPa
21 LoaderPumpP. MAX Loader pump oil pressure (max) MPa
22 LoaderPumpP. AVE Loader pump oil pressure (average) MPa
23 HYD OIL TMP.MAX Hydraulic oil temperature (max) degC
24 HYD OIL TMP.AVE Hydraulic oil temperature (average) degC
25 HYD OIL TMP.MIN Hydraulic oil temperature (min) degC
26 ST PUMP P MAX S/T pump oil pressure (max) MPa
27 ST PUMP P AVE S/T pump oil pressure (average) MPa
28 TM MAIN P MAX T/M main pressure (max) MPa
29 TM LUB P MAX T/M lubricating oil pressure (max) MPa
30 TM LUB TMP. MAX T/M lubricating oil temperature (max) degC
31 TC IN P.MAX T/C inlet pressure (max) MPa
32 TC OUT P.MAX T/C outlet pressure (max) MPa
33 TC OIL TEMP MAX T/C oil temperature (max) degC
34 TM MOD P MAX Mod/C pressure (max) MPa
35 F.BRAKE P MAX Front brake charge pressure (max) MPa
36 R.BRAKE P MAX Rear brake charge pressure (max) MPa
37 Travel Speed Max Travel speed (max) km/h
38 ECO ON Engine ECO mode operating time sec
WA1200-6 30-141
Electrical system

39 Atmos. Pres.Ave Ambient pressure (mean) hPa
40 AMBIENT TMP.MAX Outside air temperature (max) degC
41 AMBIENT TMP.AVE Outside air temperature (average) degC
42 AMBIENT TMP.MIN Outside air temperature (min) degC
43 0 - 30 ton Loadmeter value : 30 tons or less times
44 - 31 ton : - 31 tons times
59 50 - ton : 50 tons or more times
30-142 WA1200-6
Electrical system
Table 2.1: Transmission trend data

E/G use time by exhaust temp : from 700 degC to 750
1 Exh.Temp LF 700- sec
degC (L-1,2,3,4)
degC (L-1,2,3,4)
E/G use time by exhaust temp : 800 degC or more
(L-1,2,3,4)
E/G use time by exhaust temp : from 700 degC to
4 Exh.Temp LR 700- sec
750degC (L-5,6,7,8)
E/G use time by exhaust temp :f rom 750 degC to 800
degC (L-5,6,7,8)
(L-5,6,7,8)
7 Exh.Temp RF 700- sec
degC (R-1,2,3,4)
E/G use time by exhaust temp :f rom 750 degC to 800
degC (R-1,2,3,4)
(R-1,2,3,4)
10 Exh.Temp RR 700- sec
degC (R-5,6,7,8)
degC (R-5,6,7,8)
(R-5,6,7,8)
13 F Fill Time T/M F cluch fill up time (average) msec
14 R Fill Time T/M R cluch fill up time (average) msec
15 1st Fill Time T/M 1st cluch fill up time (average) msec
16 2nd Fill Time T/M 2nd cluch fill up time (average) msec
17 3rd Fill Time T/M 3rd cluch fill up time (average) msec
18 F Trg. Time T/M F cluch trigger time (average) msec
19 R Trg. Time T/M R cluch trigger time (average) msec
20 1st Trg. Time T/M 1st cluch trigger time (average) msec
21 2nd Trg. Time T/M 2nd cluch trigger time (average) msec
22 3rd Trg. Time T/M 3rd cluch trigger time (average) msec
23 TC Oil T.120- T/C use time by oil temp : from 120 degC to 130 degC sec
24 TC Oil T.130- T/C use time by oil temp : from 130 degC to 140 deg C sec
25 TC Oil T.140- T/C use time by oil temp : 140 degC or more sec
26 Brake T.120- Brake use time by oil temp : from 120 degC to 130 degC sec
Brake use time by oil temp : from 130 degC to 140 deg
27 Brake T.130- sec
C
28 Brake T.140- Brake use time by oil temp : 140 degC or more sec
WA1200-6 30-143
Electrical system
Table 2.2: Vehicle used trend data

1 Tire Srip counttime Frequency of tire slip time
2 TM Cutoff SW time T/M cut off SW ON used time sec
3 VHCL SPD SW time Vehicle speed control SW ON used time sec
4 MCN SPDSET - 4 km Vehicle speed set time by 4 km/h or less sec
Vehicle speed set time by from 4 km/h to
5 MCN SPDSET - 6 km sec
6 km/h
8 km/h
10 km/h
Vehicle speed set time by 10 km/h or
8 MCN SPDSET 10 km - sec
more
Driving performance set time by 30 ton
9 DRV PWR - 30 ton sec
or less
Driving performance set time by from 30
ton to 50 ton
ton to 70 ton
ton to 110 ton
Driving performance set time by 110 ton
13 DRV PWR 110 ton - sec
or more
14 THR - 20 % DC on Throttle lock sw set time by 20 % or less sec Auto decel on
Throttle lock sw set time by from 20 % to
15 THR - 40 % DC on sec Auto decel on
40 %
60 %
80 %
18 THR 80 % -DC on Throttle lock sw set time by 80 % or more sec Auto decel on
19 THR - 20 % DC off Throttle lock sw set time by 20 % or less sec Auto decel off
20 THR - 40 % DC off sec Auto decel off
40 %
60 %
80 %
23 THR 80 % -DC off Throttle lock sw set time by 80 % or more sec
24 Manualshift time Manual shift used time sec
25 Semi-auto Loose Semi auto SW set time (Loose) sec Loose mode
26 Semi-auto Rock Semi auto SW set time (Rock) sec Rock mode
27 Active PWRUP off Active Power cancel SW used time sec
30-144 WA1200-6
Electrical system
Table 3.1:Auto snap shot monitor items (trigger items)

No. Item FAULT CODE
1 Coolant temperature is high CA146
2 Left bank front intake temperature is extremely high CA155
3 Right bank front intake temperature is extremely high CA158
4 Left bank rear intake temperature is extremely high CA162
5 Right bank rear intake temperature is extremely high CA165
6 Engine oil temperature is extremely high CA214
7 Coolant pressure sensor signal is extremely low CA228
8 Eng Overspeed CA234
9 Fuel temperature is high CA261
10 Engine oil pressure is extremely low CA415
11 Engine oil temperature is high CA421
12 Crankcase internal pressure is extremely high CA556
13 Left bank front intake temperature rises abruptly CA783
14 Left bank No. 1 cylinder exhaust temperature is high CB2121
22 Right bank No. 1 cylinder exhaust temperature is high CB2131
30 Right bank front intake temperature rises abruptly CA2157
31 Left bank rear intake temperature rises abruptly CA2158
32 Right bank rear intake temperature rises abruptly CA2159
33 Parking brake dragging detected 989S00
34 T/C oil temperature overheat (120 °C) b@CENS
35 Hydraulic Oil Overheat B@HANS
36 Brake Oil Overheat B@C6NS
37 Front brake oil pressure drops 2G42ZG
38 Rear brake oil pressure drops 2G43ZG
39 T/M overrun alarm 1540N1
40 Manual snapshot MFA0
WA1200-6 30-145
Electrical system
Table 3.2:Manual snap shot monitor items

1 TIME Time from snapshot generation sec
2 ENG.SPEED Engine speed rpm
3 TM ENG.SPEED Engine speed (TM calculationvalue) rpm
4 FUEL INJECT. Fuel injection rate mm3/st
5 RAIL PRE. Fuel rail pressure MPa
6 BLOW-BY PRE. Blow-by pressure kPa
7 BOOST PRE. Boost pressure kPa
8 ENG. OIL TEMP. Engine oil temperature degC
9 ENG. OIL PRE. Engine oil pressure kPa
10 COOLANT TEMP. Engine coolant temperature degC
11 Exh. TEMP. LF Exhaust temperature (L-1,2,3,4 max) degC
12 Exh. TEMP. LR Exhaust temperature (L-5,6,7,8 max) degC
13 Exh. TEMP. RF Exhaust temperature (R-1,2,3,4 max) degC
14 Exh. TEMP. RR Exhaust temperature (R-5,6,7,8 max) degC
15 Accelerator Pos. Accelerator position. %
16 PPC OIL PRES PPC oil pressure MPa
17 LOADER PUMP PRES Loader pump pressure MPa
18 HYD. OIL TEMP Hydraulic oil temperature degC
19 Lever V. Boom1 Boom lever potentiometer voltage mV
20 Lever V. Bkt1 Bucket lever potentiometer voltage mV
21 Boom Bottom P. Boom bottom Pressure. MPa
22 Boom Head P. Boom haed Pressure. MPa
23 Boom Angle Boom angle deg
24 ST PUMP PRES S/T pump presssure MPa
25 AJSS L. V. Boom1 AJSS lever potentiometer voltage mV
26 Flame Angle Frame angle deg
1 o F1, 2 o F2, 3 o F3
27 SHIFT INDICATOR Present Shift position – -1 o R1, -2 o R2, -3 o
R3
28 T/M Out Speed T/M outlet shaft speed rpm
29 VEHICLE SPEED Travel speed km/h
30 T/C OIL TEMP. T/C oil temperature degC
31 M/C Out Speed Mod/C output shaft speed rpm
32 M/C SLIP RATE Mod/C slip ratio %
33 M/C Press Mod/C oil pressure MPa
34 F Brake Press F brake charge oil pressure MPa
35 R Brake Press R brake charge oil pressure MPa
36 Brake Oil Temp Brake oil temperature degC
37 L BRAKE PRESS Left brake oilpressure MPa
38 Right Brake SW Right brake SW ON/OFF –
39 AMB. AIR TEMP. Ambient air temperature degC
40 ECO. MODE ECO. Mode ON/OFF –
30-146 WA1200-6
Electrical system
Inspection and maintenance of KOMTRAX Plus controller
Inspection and maintenance of KOMTRAX Plus controller 30-147
1. Time of inspection: When performing inspec-

tion and maintenance of the machine
When servicing the machine, perform system
inspection at the same time.
2. Inspection item
a Perform inspection, check, and take reme-
dies if problems are found.
1) At check before starting (Ask the customer to
perform this check too.)
1] Check if the installed condition of
sensors, etc. is normal.
(Check for loosening, damage, and
contamination)
2] Check the wiring harnesses, cables, and
connectors for loosening and damages.
3] Check for oil leaks or gas leaks from the
sensor mountings.
2) Every 1,000 hours service
1] Communication antenna (if equipped)
q Check for looseness or play at the an-
tenna mounting.
q Check for damage, looseness, or play
in the antenna body.
q If any failure is found, replace the an-
tenna.
3) Maintenance when required
1] Check each sensor if downloaded value
is abnormal.
3. Remedy
If any failures are found, repair, replace, or rein-
stall (retighten).
WA1200-6 30-147
Electrical system
Initial setting procedure for KOMTRAX Plus controller
Initial setting procedure for KOMTRAX Plus controller 30-148
a Initial setting equipment for KOMTRAX Plus 1. Check of machine information, engine infor-
controller mation, transmission controller information
Symbol Part No. Part name and controller information
1
799-608-3211 CD-ROM a This step is a work performed on the whole
799-608-3220 Wiring harness machine.
ZB Laptop type personal com- Check and record the machine information,
Commercially
2 puter (PC):
available engine information, KOMTRAX Plus
Windows98/2000/Me/XP
controller information, and ORBCOMM
a Before starting full operation after completion of terminal information.
local assembly or before resuming operation af- No. Information to be checked
ter storage for a long period, initialize the 1 Machine model
KOMTRAX Plus controller according to the fol- 2 Machine serial No.
lowing procedure. 3 Current service meter reading
a Machine data collected by the KOMTRAX Plus 4 Engine serial No.
5 Transmission serial No.
controller are stored and managed in the Web- 6 KOMTRAX Plus controller serial No.
CARE database. ORBCOMM terminal serial No.
To ensure trouble-free processing in WebCARE, 7
[Only for machines equipped with ORBCOM]
the KOMTRAX Plus controller settings must be
coherent. To process the data smoothly on the
2. Connection of personal computer
WebCARE, it is necessary to set the KOMTRAX
a This step is a work performed in the opera-
Plus controller consistently. If it is not set
tor's cab.
correctly, data will not be taken into the
1) Make sure that starting switch is in the OFF
WebCARE and data in the KOMTRAX Plus
position.
controller may not be utilized. Accordingly, be
k Before connecting or disconnecting
sure to perform the initialization.
the PC, be sure to turn the starting
a For the installation procedure of the KOMTRAX
switch to the OFF position.
Plus initial setting program to a personal com-
2) Using harness ZB1, connect personal
puter, refer to the operation and maintenance
computer ZB2 and download connector DL1.
manual being bundled with the service kit ZB1.
a Connect it to RS232C terminal on the PC.
a Since the service menu of the monitor panel will
be used in the following procedure, read "Spe-
cial functions of monitor panel" and understand
the operating procedure in advance.
a The initial setting procedure covers both the OR-
BCOM specification and the ORBCOM-less
specification. When using the ORBCOM-less
specification unit, follow the procedure while by-
passing those prepared only for the ORBCOM
specification.
a Check each step of the setting work referring to
the "KOMTRAX Plus initial setting work check
sheet".
a Information such as models shown in the figures
may not be identical with actual ones.
30-148 WA1200-6
Electrical system
3. Start-up of KOMTRAX Plus initial setting tool 4. Initial setting of VHMS controller
a This step is a work performed in the opera- (Ver. 3.5.2.1 or older version)
tor's cab (on the PC). a This work is done inside the cab (from PC).
1) Turn on the PC and start the OS. a It is prohibited in the initial setting to modify
2) Click the icon of [KOMTRAX Plus Initial the data of service meter [SMR].
Setting Tool] on the PC to start the [Machine Information]
KOMTRAX Plus initial setting tool. 1) The [Machine information] tab is displayed
Important first in the [Data clear and Set up] menu, and
a The setting screen varies with the version the screen data are read automatically.
No. of the KOMTRAX Plus setting tool. 2) The default initial screen appears.
a When using a tool before Ver. 3.5.2.1 (Initial screen set at the delivery time)
(CD-ROM), set the KOMTRAX Plus in 3) Check all the data.
step 4.
a When using the updated tool (Ver. 3.5.2.1
or after), configure the KOMTRAX Plus in
step 5.
a It is recommended to download the latest
KOMTRAX Plus setting tool from the We-
bCARE and update your tool. (Related
material: SERVICE MATE SMP-623)
3) Input the 10-digit service ID in [Service ID].
a Service ID: 7826112000
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press [OK] button to proceed to the setting
screen.
WA1200-6 30-149
Electrical system
4) If the information in the [Date/Time] box is not 5) If the information in the [Machine information]
correct, change it according to the following box is not correct, change it according to the
procedure: following procedure:
1] Press the [Edit] button (1) in the 1] Press the [Edit] button (2) in the [Machine
[Date/Time] box to display the correction information] box to display the correction
screen. screen.
2] The pull-down menu appears in the 2] When changing the variation code, press
[TimeZone] box. Press the [r] button to the [r] button in the pull-down menu to
scroll the screen and select the correct select the code to be changed.
information. q STD: Standard boom
q HL: High lift boom
q EHL: Extra high lift boom
3] When changing the Serial No., Engine
Serial No. 1, or Engine Serial No. 2, input
the correct No. directly in the corre-
sponding box.
q Engine Serial No. 1: Engine serial No.
q Engine Serial No. 2: Transmission se-
rial No.
4] Correct the information and press the
[OK] button.
3] Check the current time. If it is wrong,

correct it.
q Input the correct time directly in the
corresponding box.
4] Correct the information and press the
[OK] button.
30-150 WA1200-6
Electrical system
6) After checking and changing all the data of 4-1.Setting of PLM data
[Machine information], press [Apply] button 1) Open the [PLM] tab and go to the setting
(3) to settle the setting. screen. In the default mode (which was set
a If [Apply] button (3) is pressed, the screen when delivered), collection of the data is
for checking the setting appears. Check started at 0:00 AM to collect the data of 1
the setting again and press the [OK] but- day.
ton when the setting is correct. 2) Press the [Edit] button (5) to go to the screen
for setting the collection start time and collec-
tion unit (day).
3) Select an item to be changed (Start time or

Interval) and set it with (er)(6) buttons (6).
You may input a value directly.
4) Press [OK] button (7).
WA1200-6 30-151
Electrical system
4-2.Setting of ORBCOMM communication 2) To change setting of [SHORT TREND ANAL-

[For ORBCOMM specification only] YSIS], follow the procedures below.
q Open the [Communication Setting] tab. 1] Select [SHORT TREND ANALYSIS] on
q Check all the data. the screen and press the [Edit] button (5)
at the left lower part of the [File Transfer
Setting] block to display the setting
screen.
2] Change the setting and then press the
[OK] button.
a When setting up, select [20h] in the
[SMR] box, and set the function to
[ON].
1) To change the setting of [SHORT FAULT

HISTORY], follow the procedure below.
1] Select [SHORT FAULT HISTORY] on the
screen and press the [Edit] button (5) at
the left lower part of the [File Transfer
screen. 3] The confirmation screen appears again. If
2] Change the setting and then press the the setting is correct, press the [Y] button
[OK] button. to finish setting.
a When setting up, select [Occurrence] 4] After checking and changing all the data,
in the [Timing] box, and set the func- press the [Exit] button at the right bottom
tion to [ON]. of the screen to turn the software OFF.
30-152 WA1200-6
Electrical system
3) To change the setting of [Satellite Setting],

follow the procedure below.
1] Press the [Edit] button (6) in the [Satellite
screen.
2] Bring GCC Code to the applicable area
and then press the [OK] button.
2] Check that OK is displayed at the left end

and confirm that setting is finished
normally, and then press the [Close]
button.
GCC codes and applicable areas

Code Applicable area
1 USA
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan
4) After checking and changing all the data in

[Communication Setting], press the [Apply]
button (7) to settle the setting.
a If the [Apply] button is pressed, the
screen for checking the setting appears.
Check the setting again and press the
[OK] button when the setting is correct.
1] When the data are cleared, the system

asks you if you will download the current
data file. Since the file is not necessary for
setting up, press the [No] button.
WA1200-6 30-153
Electrical system
3] Press the [Apply] button. 5. Initial setting of KOMTRAX Plus controller

q Only the changed data are displayed. (Ver. 3.5.2.1 or later version)
Check them and press [OK] button a This work is done inside the cab (from PC).
(9). a It is prohibited in the initial setting to modify
the data of service meter [SMR].
1) Select [VHMS Setting] and then press [Next]
button.
4] The OK screen appears. Press [Close]

button (10), and then press the [Exit]
button to finish the VHMS Setting Tool 2) Select [Set up & All clear] and press the
and turn the starting switch OFF. "Next" button.
30-154 WA1200-6
Electrical system
3) Check the machine information. If it does not 4) Select the time zone.
need to be corrected, press the "Next" 5) Input the local time.
button. 6) If the DST (Daylight Saving Time) is used
now, select it and press the "Next" button.
a If the DST is selected, the clock is ad-
vanced 1 hour automatically, thus the
time must be corrected again.
a If the KOMTRAX Plus was installed addi-

tionally, the information of [Serial No.] etc.
must be input.
7) Set the GCC Code to the applicable area and

then press the "Next" button.
GCC Code Area Remarks
N. America (*1) *1: Except U.S. Territo-
1 C.S. Americas ries in Micronesia and
Faroe Islands Midway Island
Europe (*2)
Middle East *2: Except Faroe Islands
Asia (*3) *3: Except Japan
120
Africa (*4) *4: `Globalgram mode’ is
Oceania required
CIS
130 Japan
WA1200-6 30-155
Electrical system
8) Finally, check the new setting displayed on 6. Checking saving operation of KOMTRAX
the screen. To confirm, press the "Apply" Plus controller
button. 1) Turn the starting switch to the OFF position.
2) Check to ensure that power to KOMTRAX
Plus controller has been completely shut off
by observing the 7-segment LED of the
controller.
a When the starting switch is turned to
OFF, KOMTRAX Plus controller saves /
updates data.
a For several seconds after the starting
switch is turned to OFF position, power is
retained for saving operation. Ensure that
the 7-segment LED of the controller has
completely gone out.
9) A message is displayed, asking you whether

or not to keep the previous setting. Select
"No" if the previous setting is no longer
needed.
10)After finishing the work of changing the

contents of initialization, press the "OK"
button to finish the program.
30-156 WA1200-6
Electrical system
7. Performing Quick Pm Clinic 6) Operate the switches and levers at each

1) Start the engine and run it at low idle. execution time according to the " Operating
2) Set the lock lever in the FREE position. procedure for quick Pm Clinic" shown in the
3) Set the machine management (multi) monitor following table.
to display the service menu selection screen. a The execution times are displayed on the
a See "Functions and operation of machine machine maintenance (multi) monitor.
management (multi) monitor". k The work equipment is operated and
4) Select [Snapshot Trigger] and press "Selec- the machine travels actually during the
tion" (F6) switch. quick Pm Clinic, so ensure the safety
around the machine during the work.
5) Continue the operation on the screen to start

the snap shot. Important
a While the following screen is displayed, The data of the Quick Pm Clinic is recorded
press [F5] (Yes), and the check message only once. If the Quick Pm Clinic is executed
is displayed. again, the current data are overwritten.
a Before starting the snap shot operation, Executing the Quick Pm Clinic overwrites
fully understand the operating procedure data. Accordingly, be sure to save the data in
for the snap shot. the personal computer after executing the
q See Structure and Operation, "Multi Quick Pm Clinic, referring to "8. Downloading
Monitor". of set data".
7) Using the analysis tool, read the data of the

Quick Pm Clinic.
a For the usage of the analysis tool, see the
operation and maintenance manual.
WA1200-6 30-157
Electrical system
8. Quick Pm Clinic implementation procedure

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
800 rpm Eng Low Engine Full Engine Full Eng High Engine Full Eng Low Eng High Engine Full Eng Low
Operat- Engine idle Bucket Steering Idle T/C Stall idle Idle Full Stall idle
ing condi- Tilt Back Relief
tions and Relief
sequence
T/M
N N N N N F3 N N F3 N
Shift switch
(Min-
Operat- 0.0 0.5 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5
utes)
ing condi-
(Min-
tions -5.5 -5.0 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0
utes)
1-1 Engine speed 1/4 1/4 1/4 1/4 1/4 1/4 a
1-2 Engine oil pres- 1/4 1/4

sure
1-3 Blow–by Pres- 2/4 a

sure
1-4 Boost pressure 2/4
1-5 Ambient Temper- 2/4

ature
2-1 T/C Inlet Pres- 3/4

sure
2-2 T/C Outlet Pres- 3/4

sure
3-1 T/M Main Relief 3/4

Pressure
3-2 T/M Lubricating 3/4

Oil Pressure
3-3 T/M Mod Oil 3/4

Pressure
4/1 Steering circuit 4/4

relief pressure
5-3 Brake Charge 4/4

Cut-in (*1)

Cut-out (*1)
6-1 Work equipment 4/4

relief pressure
6-2 PPC Oil Pres- 4/4

sure
(*1) Depress the brake pedal for more than 10 times to lower the brake accumulator circuit pressure to below the cut-in
pressure before measuring the brake accumulator charge cut-in and cut-out oil pressures while running the engine at
low idle.
k The range of error in operation condition switching time is ±5 seconds.
Value: Indicates the page number of the Pm Clinic display on the multi monitor.
a Read when a PC is not used.
30-158 WA1200-6
Electrical system
9. Download of setting data

1) Turn the starting switch to ON position.
2) Click the icon of [KOMTRAX Plus Analysis
Tool] on the PC to start the KOMTRAX Plus
analysis tool.
a Input [User Name] and [Password].
a For the operation procedures, refer to the
operation manual for the KOMTRAX Plus
Technical Analysis Tool.
3) Using the [Download] function, download the

data currently recorded in the KOMTRAX
Plus controller to the personal computer.
a Make sure that downloading has complet-
ed before proceeding to the next step.
WA1200-6 30-159
Electrical system
10. Check of downloaded data

tor's cab (on the PC).
1) Check the setting data by using [View] func-
tion.
a Display the graph using the "View" func-
tion of the analysis tool. Measure the data
of each item.
(Example: Engine speed)

a Make sure that the [MFA0] code at the
time when the snapshot was operated is
displayed in [Fault History].
a Make sure that the snap shot data are re-
corded.
2) After checking the setting data, terminate

[KOMTRAX Plus Technical Analysis Tool].
30-160 WA1200-6
Electrical system
11. Disconnecting the PC 12. Report to Komatsu

1) Make sure that starting switch is in the OFF After completing steps 1 to 11 successfully, send
position. the "KOMTRAX Plus/WebCARE setting notifica-
k When connecting and disconnecting tion form" to KOMTRAX Plus/WebCARE
the PC, be sure to turn the starting Support Center of Komatsu, Tokyo.
switch to the OFF position. a Since Komatsu has to set the receiving side
2) Shutdown the OS of PC ZB2 and then turn of the satellite communication, be sure to in-
off the PC power. form Komatsu of the completion of the set-
3) Disconnect the harness ZB1 from the down- ting.
load connector DL1. a Send the KOMRAX Plus data by Notes
(LAN) or E-mail (WAN).
Komatsu KOMTRAX Plus/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)
E-mail: webcare@komatsu.co.jp
WA1200-6 30-161
Electrical system
[For storage] Date of setting: Year Month Day

KOMTRAX Plus initial setting work check DB/branch
sheet name:
Filled by:
Setting step Check item Results
Model name
Serial No.
Check of nameplates of chassis and
1 Engine serial No.
components
Transmission controller serial No.
KOMTRAX Plus controller S/No.
Connection of PC with KOMTRAX Plus

2 Is the connection secure? yes no
controller
Is it operating normally?
Checking operation of KOMTRAX Plus
3 (Displays decimal counting in ascending-order succeeding yes no
controller
to rotation)
Start-up of KOMTRAX Plus initial setting Is "Data Clear and Set up" selected for the setting tool
4 yes no
tool mode?
Is model name identical with machine body? yes no
Initial setting procedure for KOMTRAX
Plus controller Is machine body serial No. correctly entered? yes no
Is engine serial No. correctly entered? yes no
5 (Setting of machine information)
In this step, basic machine body infor- Is today's date entered? yes no
mation are set on KOMTRAX Plus con- Is current time entered? yes no
troller)
Is SMR correctly entered? yes no
6 Saving of set items Is LED (7-segment) turned off? yes no
7 Check of KOMTRAX Plus function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the switch

8 Performing Quick Pm Clinic yes no
pressed?
9 Saving operation of KOMTRAX Plus Is LED (7-segment) turned off? yes no
10 Downloading Is LED operation normal? yes no
Are all files downloaded? yes no

Cat-
The time downloaded (Reference wrist watch) Hour egor
y
11 Check of download data [Check of data]
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot? yes no
12 Saving operation of KOMTRAX Plus Is LED (7-segment) turned off? yes no
30-162 WA1200-6
Electrical system
[For storage] Date of setting: Year Month Day

ORBCOMM Station Establishment Check DB/branch
Sheet name:
Filled by:
Setting step Check item Results
Machine model
Serial No.
Check of nameplates of chassis and Engine serial No.

1
components Transmission serial No.
KOMTRAX Plus controller S/No.
ORBCOMM controller serial No.
Connection of PC with KOMTRAX Plus

2 Is the connection secure? yes no
controller
Is it operating normally?
Checking operation of KOMTRAX Plus
3 (Displays counting in ascending-order succeeding to rota- yes no
controller
tion)
Start-up KOMTRAX Plus initial setting
4 Is "Set up" selected for the setting tool mode? yes no
tool
Initial setting procedure for KOMTRAX Enter set value of S.Fault History.
Plus controller
Execution of communication On Off
1. Setting for communication Number of communication (Default: 8) hrs
(Machine information and PLM
have been set) Enter set value of S.Trend Analysis.
5 Interval (Default: 20H) hrs
Enter set value of S. Payload data.
Time to start collection
Collection interval (Number of days) day
2. Setting for start of communication Is GCC code set? (130 for Japan) yes no
6 Saving of set items Is LED (7-segment) turned off after saving operation? yes no
How is decimal point display in KOMTRAX Plus monitor
Check of operation of ORBCOMM con-
7 (7-segment)? yes no
troller
(Off, On, long/short blinking)
WA1200-6 30-163
Electrical system
30-164 WA1200-6
Electrical system
Precautions for replacing KOMTRAX Plus controller
Precautions for replacing KOMTRAX Plus controller 30-165
a Setting equipment for replacement of 2. Connection of PC

KOMTRAX Plus controller a This step is a work performed in the opera-
Symbol Part No. Part name tor's cab.
1] Make sure that starting switch is in the
799-608-3211 CD-ROM OFF position.
k Before connecting or disconnect-
1
799-608-3220 Wiring harness
ZB ing the PC, be sure to turn the start-
Laptop type personal computer
Commercially ing switch to the OFF position.
2 (PC):
available 2] Using harness ZB1, connect personal
(Windows98/2000/Me/XP)
computer ZB2 and download connector
a When the KOMTRAX Plus controller needs to be
DL1.
replaced, set it before removing it and set the in-
stalled new KOMTRAX Plus controller according
to the following procedure.
a Machine data collected by the KOMTRAX Plus
controller are stored and managed in the Web-
CARE database.
To ensure trouble-free processing in WebCARE,
the KOMTRAX Plus controller settings must be
coherent. To process the data smoothly on the
WebCARE, it is necessary to set the KOMTRAX
Plus controller consistently. If it is not set
correctly, data will not be taken into the
WebCARE and data in the KOMTRAX Plus
controller may not be utilized. Accordingly, be
sure to perform the setting for replacement.
a Check each step of the setting work referring to
the "KOMTRAX Plus initial setting work check 3. Check, saving, and writing of information set in
sheet". KOMTRAX Plus controller (Ver. 3.5.2.1 or later)
a Information such as models shown in the figures a This step is a work performed in the opera-
may not be identical with actual ones. tor's cab (on the PC).
a Transfer the set data of the KOMTRAX Plus
[Work before replacement of KOMTRAX Plus controller to be replaced to the PC and then
controller] write it in the newly installed KOMTRAC Plus
1. Download of the remaining data controller.
tor's cab (on the personal computer).
a Using the [Download] function, download the
data currently recorded in the KOMTRAX
Plus controller to the PC.
a For the operating procedures, see Initializa-
tion procedures for KOMTRAX Plus control-
ler, "9. Downloading of set data".
WA1200-6 30-165
Electrical system
3-1. Confirmation and saving of VHMS

controller setting information prior to
replacement
1) Connect the PC and start the VHMS initial
setting tool.
a See the “VHMS controller initial setting
procedure” for this operation.
2) Select [Save/Load] and press [OK] button.
5) Reconfirm the information and then press

[OK] button to save the information.
3) Confirm every information before the

replacement.
4) Select [Save] from [File] of the menu.
6) Select [Exit] from [File] of the menu to end the
VHMS setting tool.
7) Disconnect the PC.
a Refer to “11. Disconnection of Personal
computer” in “VHMS controller initial set-
ting procedure”.
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.
30-166 WA1200-6
Electrical system
3-2. Loading the setting information to the 4) Currently saved information will be
replacing VHMS controller displayed. Press [OK] button.
1) Connect the PC again and start the VHMS
initial setting tool.
a See the “VHMS controller initial setting
procedure” for this operation.
2) Select [Save/Load] and press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
3) Select [Load] from [File] of the menu.
7) After adjusting time, press [OK] button.
WA1200-6 30-167
Electrical system
8) Press [Apply] button to display contents of 9) The confirmation screen will ask whether or
the setting. Check the setting again and, if it not the data before the above setup is to be
is acceptable, press [OK] button. saved. Press [NO] button.
a It is not necessary to save the data before
the setting.
10)The setup result is displayed. Confirm the

contents and press [Close] button.
11)The setup result is displayed. Confirm the

contents and press [Close] button.
30-168 WA1200-6
Electrical system
4. Check, saving, and writing of information set in 4) Check all the information before replacing
KOMTRAX Plus controller (Ver. 3.5.2.1 or later) the controller and press the "Save" button.
tor's cab (on the PC).
a Transfer the set data of the KOMTRAX Plus
controller to be replaced to the PC and then
write it in the newly installed KOMTRAC Plus
controller.
4-1. Check and saving of information set in

KOMTRAX Plus controller to be replaced.
1) Connect the PC and start the KOMTRAX
Plus initial setting tool.
a See "Initial setting procedure for
KOMTRAX Plus controller".
2) Select [When KOMTRAX Plus needs to be
replaced] and press the "Next" button.
5) Select [Exit] from [File] of the menu to end the

KOMTRAX Plus initial setting tool.
6) Disconnect the PC.
a See "11. Disconnection of Personal Com-
puter" in "Initialization procedure for
7) Turn the PC OFF.
8) Replace the KOMTRAX Plus controller.
4-2. Writing of set information to the new

replaced VHMS controller
1) Connect the PC again and start the
KOMTRAX Plus setting tool.
a See "Initial setting procedure for
3) Select [Save Current Setting before replace- 2) Select [When KOMTRAX Plus needs to be
ment of KOMTRAX Plus controller] and replaced] and press the "Next" button.
press the "Next" button.
WA1200-6 30-169
Electrical system
3) Select [Use Previous setting after replace- 6) The system asks you if you will save the
ment of KOMTRAX Plus controller] and previous data. Press the "NO" button.
press the "Next" button. a Usually, you do not need to save the pre-
vious data.
4) The saved information is displayed. Press

the "Next" button.
7) The above completes modification of the
setting. Press [OK] button to end the
KOMTRAX Plus initial setting tool.
5) Set the time and press the "Apply" button.
30-170 WA1200-6
Electrical system
[Work after replacement of KOMTRAX Plus controller]

a Execute the quick Pm referring to "7. Executing
quick Pm" in "KOMTRAX Plus controller initial
setting procedure".
a Download the data referring to "9. Download of
setting data" in "KOMTRAX Plus controller initial
setting procedure".
a After completing the setting after the replace-
ment, send the check sheet to KOMTRAX
Plus/WebCARE Support Center of Komatsu, To-
kyo.
a Send the data downloaded before and after re-
placing the KOMTRAX Plus controller by Notes
(LAN) or E-mail (WAN).
Komatsu KOMTRAX Plus/WebCARE Support
Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)
E-mail: webcare@komatsu.co.jp
WA1200-6 30-171
Electrical system
30-172 WA1200-6
Electrical system
Measurement procedure by downloading data in KOMTRAX Plus controller
Measurement procedure by downloading data in KOMTRAX Plus

controller 30-173
1. Connection of PC
1) Make sure that starting switch is in the OFF
position.
k Before connecting or disconnecting
the PC, be sure to turn the starting
switch to the OFF position.
2) Using harness ZB1, connect personal
computer ZB2 and download connector DL1.
2. Run engine
1) Check that the screen of the multi monitor
does not display any abnormality.
2) Prepare the Pm Clinic sheet. Check safety
around the machine, sound the horn, and
2) Operate the switches and levers at each
start the engine.
execution time according to the " Operating
3) Turn the steering lock switch to the OFF posi-
procedure for quick Pm Clinic" shown in the
tion.
following table.
4) Set the lock lever to the FREE position.
a The execution times are displayed on the
multi monitor.
k The work equipment is operated and
3. Selection of multi monitor display
1) Set the multi monitor to display the service
the machine travels actually during the
quick Pm Clinic, so ensure the safety
a See Structure and Operation, "Multi Mon-
around the machine during the work.
itor".)
2) Select "Snap shot".
4. Performing snap shot operation

1) Continue the operation on the screen to start
the snap shot.
a While the following screen is displayed,
press the "Yes" (F5) button, and the
check message is displayed.
a Before starting the snap shot operation,
fully understand the operating procedure
for the snap shot.
WA1200-6 30-173
Electrical system
5. Measurement procedure by downloading data in KOMTRAX Plus controller

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
800 rpm Eng Low Engine Full Engine Full Eng High Engine Full Eng Low Eng High Engine Full Eng Low
Operat- Engine idle Bucket Steering Idle T/C Stall idle Idle Full Stall idle
ing condi- Tilt Back Relief
tions and Relief
sequence
T/M
N N N N N F3 N N F3 N
Shift switch
(Min-
Operat- 0.0 0.5 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5
utes)
ing condi-
(Min-
tions -5.5 -5.0 -2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 2.0
utes)
1-1 Engine speed 1/4 1/4 1/4 1/4 1/4 1/4 a
1-2 Engine oil pres- 1/4 1/4

sure
1-3 Blow–by Pres- 2/4 a

sure
1-4 Boost pressure 2/4
1-5 Ambient Temper- 2/4

ature
2-1 T/C Inlet Pres- 3/4

sure
2-2 T/C Outlet Pres- 3/4

sure
3-1 T/M Main Relief 3/4

Pressure
3-2 T/M Lubricating 3/4

Oil Pressure
3-3 T/M Mod Oil 3/4

Pressure
4/1 Steering circuit 4/4

relief pressure

Cut-in (*1)

Cut-out (*1)
6-1 Work equipment 4/4

relief pressure
6-2 PPC Oil Pres- 4/4

sure
(*1) Depress the brake pedal for more than 10 times to lower the brake accumulator circuit pressure to below the cut-in
pressure before measuring the brake accumulator charge cut-in and cut-out oil pressures while running the engine at
low idle.
k The range of error in operation condition switching time is ±5 seconds.
Value: Indicates the page number of the Pm Clinic display on the multi monitor.
a Read when a PC is not used.
30-174 WA1200-6
Electrical system
6. Downloading of snap shot data

1) Turn the PC ON and start the OS.
2) Click the icon of [KOMTRAX Plus Analysis
Tool] on the PC to start the KOMTRAX Plus
analysis tool.
a Input [User Name] and [Password].
3) Check the setting data by using [View] func-
tion.
a Display the graph using the "View" func-
tion of the analysis tool.
Measure the data of each item.
(Example: Engine speed)

a Make sure that the [MFA0] code at the
time when the snapshot was operated is
displayed in [Fault History].
a Make sure that the snap shot data are re-
corded.
WA1200-6 30-175
Electrical system
4) Using the [Download] function, download the

data recorded in the KOMTRAX Plus
controller to the PC.
a For the operation procedures and data
analyzing method, see the operation
manual for KOMTRAX Plus Analysis
Tool.
30-176 WA1200-6
Electrical system
Measurement procedure by multi monitor
Measurement procedure by multi monitor 30-17
1. Start engine
1) Check that the screen of the multi monitor
does not display any abnormality.
2) Prepare the Pm Clinic sheet. Check safety
around the machine, sound the horn, and
start the engine.
3) Turn the steering lock switch to the OFF posi-
tion.
4) Set the lock lever to the FREE position.
2. Check of indication of engine coolant

temperature gauge and torque converter oil
temperature gauge
1) Set the multi monitor to display the monitor
screen.
4. Measuring with "PM CLINIC MENU (1/4)"
2) Check the indication of the engine coolant
1) Display "PM CLINIC MENU (1/4)".
temperature gauge and the torque converter
2) Measure the engine speed, engine oil pres-
oil temperature gauge.
sure, engine oil temperature, and engine
coolant temperature.
a For the measurement conditions, see the
check sheet.
3. Selection of multi monitor display

Set the multi monitor to display the service menu
and select the "Pm Clinic" menu.
a For the operation method see Structure and
Operation, "Multi Monitor".
WA1200-6 30-177
Electrical system
Measurement procedure by multi monitor
5. Measuring with "PM CLINIC MENU (2/4)" 7. Measuring with "PM CLINIC MENU (4/4)"
1) Display "PM CLINIC MENU (2/4)". 1) Display "PM CLINIC MENU (4/4)".
2) Measure the engine speed, blow-by pres- 2) Measure the hydraulic oil temperature, PPC
sure, boost pressure, exhaust gas tempera- oil pressure, hydraulic oil pressure, steering
ture, ambient temperature, and fuel rail pump oil pressure, front brake oil pressure,
pressure. and rear brake oil pressure.
a For the measurement conditions, see the a For the measurement conditions, see the
check sheet. check sheet.
6. Measuring with "PM CLINIC MENU (3/4)" 8. Measuring work equipment speed and
1) Display "PM CLINIC MENU (3/4)". hydraulic drift
2) Measure the torque converter oil tempera- Using a stopwatch, scale, etc., measure the
ture,torque converter inlet pressure,torque work equipment speed and hydraulic drift.
converter outlet pressure,transmission main
pressure, transmission lubricating oil pres-
sure, and transmission modulation pressure.
a For the measurement conditions, see the
check sheet.
30-178 WA1200-6
Electrical system
Special functions of multi monitor
Special functions of multi monitor 30-179
Ordinary functions and the special functions of multi monitor 30-179

The multi monitor has the ordinary functions and special functions and displays information of various types
on the machine monitor in the middle.
Some of display items are automatically displayed according to the internal setting made of the multi monitor,
while others are displayed when a corresponding switch on the multi monitor is operated.
1) Ordinary functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
2) Special function: Service mode
Functions which the serviceman can display and operate with the special switches to perform inspec-
tion, maintenance, and troubleshooting.
Operator mode Service mode

1 Clock/engine speed display function 1 Real-time monitoring function
Monitor contrast/brightness adjusting func-
2 2 Pm Clinic function
tion
Productivity/production history display func-
3 3 Abnormality record display function
tion
4 Date/time of day adjusting function io 4 Manual snap shot function
5 Language selection function 5 Adjustment Menu
6 Maintenance monitor function 6 Option setting
7 Failure list display function 7 Maintenance monitor function
8 Load meter function 8 Unit setting function
9 Caution/warning display function 9 Memory clear function
10 Serial/GCC setting function
WA1200-6 30-179
Electrical system
Upper part of multi monitor (display portion) 30-180 Outline of operator mode 30-180
(a): Multi-information display a The operator mode is outlined below.
a When the engine is started, the battery voltage a For details of the operator mode, see "Structure,
may lower suddenly, depending on the ambient function and maintenance standard" or "Opera-
temperature and the condition of the battery. tion and Maintenance Manual".
In this case, the screen display of the machine
monitor may go off for a moment. This phenom- 1. KOMATSU logo screen
enon is not a failure, however. When starting switch is turned ON, KOMATSU
logo is displayed for two seconds.
Upper part of multi monitor (switch portion) 30-180 a After the KOMATSU logo is displayed for two
[F1]: F1 Function switch seconds, the screen changes to the standard
[F2]: F2 Function switch screen.
[F3]: F3 Function switch
[F4]: F4 Function switch 2. Standard screen display
[F5]: F5 Function switch A clock appears at the upper row on the right of
[F6]: F6 Function switch the screen and the KOMATSU logo appears at
a The function of each function switch is indicated the center.
by the icon which is displayed just above the
function switch on the screen of the multi-infor-
mation display panel (a).
a If the graphic mark of a function switch is not dis-
played, that function switch is not working.
a With the standard screen displayed, press

each [F] switch to go to the corresponding
screen.
30-180 WA1200-6
Electrical system
Screen transition from the standard screen flow
WA1200-6 30-181
Electrical system
3. Brightness/contrast q Press the [F5] switch to put "Contrast" in

For changing settings of brightness, contrast, the selected state.
and luminance of the screen, select a setting q Select the contrast with [F3] or [F4].
screen from the standard screen. q When the [F6] switch is pressed with the
1) With the standard screen displayed, press change completed, the change is entered
the [F1] switch to go to the bright- and the screen is returned to the standard
ness/contrast setting screen. screen.
q To change "Luminance" successively,
press the [F5] switch to put "Luminance"
in the selected state. (In this case, the
change made in "Contrast" is yet to be
validated.)
q If the [F1] switch is pressed, the change is
canceled before entering and the screen
returns to the standard screen.
3) Luminance selecting screen
q Select the brightness with pressing [F3]

or [F4].
q If "Brightness" only is to be changed,
press the [F6] switch to enter the setting
made for "Brightness" and return to the
standard screen.
q To change "Contrast" successively, press
the [F5] switch to put "Contrast" in the se-
lected state. (In this case, the change
made in "Brightness" is yet to be validat-
ed.) q Press the [F5] switch to put "Luminance"
q If the [F1] switch is pressed, the change is in the selected state.
canceled before entering and the screen q Select the luminance with [F3] or [F4].
returns to the standard screen. q When the [F6] switch is pressed with the
change completed, the change is entered
2) Contrast selection screen and the screen is returned to the standard
screen.
q Press the [F5] switch to return to the
"Brightness" selected state. (In this case,
the change made in "Luminance" is yet to
be validated.)
4) Return to default settings

By pressing the [F2] switch, the settings can
be reset to the default values at the shipment
from the factory.
5) By turning on the lights using the light switch,

the mode can be switched from "Daytime
mode" to "Night mode". Brightness, contrast,
and illuminance can be set for "Daytime
mode" and "Night mode" separately.
30-182 WA1200-6
Electrical system
6) Setting process flow 2) The fuel consumption measurements are

displayed on the production record display
screen, including the fuel consumption per
hour, amount of production, and work date
for each type of production.
q If the [F1] switch is pressed, the screen

changes to the productivity screen.
3) The production record should be erased line

by line.
To move to an one line up or down, press the
[F3] or [F4] switch.
a Pressing the [F6] switch on the produc-
tion history display screen changes the
screen to the erase selecting screen.
4. Productivity/productivity record display
1) When the standard screen is displayed,
press the [F2] switch to go to the productivity
screen.
Select the line of the production record to be

erased on this screen.
q If the [F2] switch is pressed, that particu-
lar production record is retained and the
q Pressing the [F2] switch on the productiv- screen returns to the production record
ity screen changes the screen to the pro- display screen.
ductivity recored screen. q If the [F5] switch is pressed, that particu-
lar production record is erased and the
screen returns to the production record
display screen.
WA1200-6 30-183
Electrical system
4) Details of fuel consumption measuring 5. User setting

screen setting flow Select menu items, including date, time of day,
user ID, and language setting, on the screen
under the date setting top screen.
1) The date setting top screen shows the date,
time of day, user ID, language setting, and
main screen selection from the top down-
ward.
a With the standard screen on the screen,
press the [F3] switch to move to the date
setting top screen.
The date setting screen is accessed by
way of the this screen.
q Press the [F3] or [F4] switch to select the

item to be set.
q Press the [F6] switch to move to the date
setting screen.
2) Courses from the date setting top screen
30-184 WA1200-6
Electrical system
6. Date/time adjustment
On the date setting screen, the selected item
changes to "Year", "Month", and "Day".
1) With the standard screen on the screen,
press the [F3] switch to move to the date
setting top screen.
2) Setting the date

On the date setting top screen, press the [F3]
or [F4] switch to move to the item to be set.
Press the [F6] switch to validate the selec-
tion.
Here, "Date" is selected.
q Pressing the [F6] switch displays the set-
ting screen for selecting "Year" of the
date.
q Select the "Set year" with [F3] or [F4].

q If "Year" only is to be changed, press the
[F6] switch to enter the setting made for
"Year" and return to the date setting top
screen.
q To change "Month" successively, press
the [F5] switch to move the row and put
"Month" in the selected state. (In this
case, the change made in "Year" is yet to
be validated.)
returns to the date setting top screen.
WA1200-6 30-185
Electrical system
3) Setting the month 7. Adjusting the time of day

Set the "Month" by selecting and entering On the time of day setting screen, the selected
one on this screen. item changes to "Hours" and "Minutes".
1) To display the time setting screen, select
"Time" with [F3] or [F4] on the date setting
top screen.
a Or, on a screen of the date setting screen
on which "Year", "Month", and "Day" have
been set, press the [F5] switch. This also
displays the time setting screen.
q Select the "Set month" with [F3] or [F4].

q When the [F6] switch is pressed with the
and the screen is returned to the date set-
ting top screen.
q To change "Day" successively, press the
[F5] switch to move the row and put "Day"
in the selected state. (In this case, the q Pressing the [F6] switch while "Time of
change made in "Month" is yet to be vali- day" is selected, displays the setting
dated.) screen for selecting "Set time" of the time
q If the [F1] switch is pressed, the change is of day.
returns to the date setting top screen. 2) Setting the hour
q Select the "Set time" with [F3] or [F4].

q If "Hours" only is to be changed, press the
[F6] switch to enter the setting made for
"Hour" and return to the date setting top
screen.
q To change "Minutes" successively, press
the [F5] switch to move the row and put
"Minutes" in the selected state. (In this
case, the change made in "Hours" is yet
to be validated.)
30-186 WA1200-6
Electrical system
3) Setting the minute 5) Details of time of day setting flow

Set the minutes while "Minutes" is put in the
selected state.
q Press the [F3] or [F4] switch to select "Set

minutes".
q When the [F5] switch is pressed, the
"Minutes" is validated and the screen
changes to the "ON/OFF" selecting state
of daylight saving time. However, when
the language is set to Japanese, "Day-
light Setting Time" is not displayed.
q When the [F6] switch is pressed with the
and the screen returns to the date setting
top screen.
4) Setting "ON/OFF" daylight saving time
q Select "ON" or "OFF" with [F3] or [F4].

"ON/OFF" setting of the daylight saving
time is entered and the screen returns to
the date setting top screen.
q This item is not displayed when the lan-
guage is set to Japanese.
WA1200-6 30-187
Electrical system
8. Inputting the user ID q Press the [F2] switch to erase the input
To set the user ID, select one on the date setting value one digit at a time.
top screen.
press the [F3] switch to move to the date set-
ting top screen.
1) For inputting the user ID, select "User ID"
with [F3] or [F4] on the date setting top
screen.
q Press the [F6] switch to display the user

ID input screen.
2) Inputting the user ID

For inputting the user ID, select a numeric
value on the screen to input one digit at a
time.
q Press the [F3] or [F4] switch to move to

the "numeric value" to be input.
q If the [F5] switch is pressed, the selected
numeric value is input.
a Repeat these steps to input the numerals
for the user ID.
q If the [F6] switch is pressed, the user ID is
entered and the screen returns to the
date setting top screen.
q If the [F1] switch is pressed, the "Numer-
als" input are canceled and the screen re-
turns to the date setting top screen.
30-188 WA1200-6
Electrical system
3) Details of user ID input process flow Input example: User ID 1234
WA1200-6 30-189
Electrical system
9. Language selection 3) Details of language setting flow

For setting the language, select language selec-
tion on the date setting top screen.
press the [F3] switch to move to the date set-
ting top screen.
1) To set the language, select "Language
setting" with [F3] or [F4] on the date setting
top screen.
10. Main SCREEN select screen
q Press the [F6] switch to display the lan-

guage setting screen.
2) Setting the language

Set the "Language" by selecting and entering
one on this screen.
Standard: "KOMATSU" displayed

Option 1: Load is displayed
Option 2: Total payload and total fuel consump-
tion is displayed
q Select the desired language with [F3] or

[F4].
q If the [F6] switch is pressed, the language
is entered and the screen returns to the
date setting top screen.
30-190 WA1200-6
Electrical system
11. Maintenance monitor 2) Resetting the maintenance monitor

The maintenance monitor displays names and After a filter or oil has been replaced with a
replacement time of filters and oils. It also has a new one, the replacement time can be reset.
function of automatically prompting the operator a On the maintenance monitor display
to perform the necessary service procedures screen, use the [F3] or [F4] switch to
when the replacement time of, for example, a move to the item to be reset and press the
filter approaches. [F6] switch to move to the reset screen
a With the standard screen displayed, press that allows you to confirm whether or not
the [F4] switch to go to the maintenance replacement has been made.
monitor screen.
1) Maintenance monitor screen
This screen displays replacement items of
filters and oils of different types according to
the replacement time.
Select whether or not the replacement has

been made on this screen.
returns to the maintenance display
screen on which the replacement time
q Press the [F5] switch to change pages. has been reset.
returns to the maintenance display
screen on which the replacement time re-
mains unchanged.
q Change pages with [F2] or [F5].

q Press the [F2] switch to return to the pre-
vious page.
q Press the [F5] switch to go to the next
page. a To continue with the resetting of the main-
q If the [F1] switch is pressed, the screen tenance monitor, press the [F6] switch
returns to the standard screen. and repeat the foregoing procedure.
WA1200-6 30-191
Electrical system
3) Details of the maintenance monitor folw 13. Load meter screen

This screen allows you to check the number of
loading sequences performed and the total
amount of loaded weight for each loaded objec-
tive.
The "load meter menu" switch on the screen
allows you to perform calibration and set the load
meter.
1) Productivity (load meter) display
1] Press [F6] located at the bottom on the
right of the standard screen.
2] The "Productivity (load meter)" screen

appears.
This screen shows the number of loading
sequences performed, the total amount of
12. Failure list display loaded weight, and the date when data
a The fault list display screen shows the abnor- was reset last for each loaded objective.
mality record. For details of the failure, see Press the [F1] switch located at the lower
the service mode. left corner of the "Productivity (load
a With the standard screen on the screen, meter)" screen to return to the standard
press the [F5] switch to move to the failure list screen.
display.
q Scroll the data with [F3] or [F4].

q Change pages with [F2] or [F5].
q If the [F1] switch is pressed, the screen re-
turns to the standard screen.
30-192 WA1200-6
Electrical system
2) Erasure on productivity (load meter) 4) Performing empty calibration

1] To erase "Type" data shown on the 1] Select "Empty calibration" shown on the
"Productivity (load meter)" screen, select screen by pressing the [F3] or [F4] switch
the "Type" data by pressing the [F3] or and validate the selection using the
[F4] switch and validate the selection "Select" [F6] switch.
using the "Select" [F6] switch.
2] When the "Empty calibration" screen

2] The "Productivity data erase" screen appears, operate the machine by
appears. following the instructions given on the
Confirm the data to be erased and press screen.
the [F5] switch. When the calibration is normally
The original "Productivity (load meter)" completed, the "Load meter menu"
screen reappears, on which "0" is shown screen reappears.
for the erased data and "Date" shows the
date of erasure.
Supplementary explanation
q Data, once cleared, can no longer be
recreated. Make sure that the data to
be cleared is the correct one before
actually clearing it.
q If TOTAL data is erased, all data of A
to E is erased.
3] Make sure that the data has been erased
and then press [F1] switch at the lower left
corner of the screen. The original stan-
dard screen reappears.
3) Displaying load meter menu

3] If the calibration is not normally termi-
Press the "Load meter menu" [F5] switch
nated, a warning screen appears. Press
located at the lower right corner of the
the [F5] switch to return to the "Load
"Productivity (load meter)" screen. The "Load
meter menu" screen and start the proce-
meter menu" screen appears.
dure over.
This screen allows you to perform the
following operations: empty calibration,
loaded calibration, calibration reset, selecting
load meter show/hide, and setting the
subtraction mode target.
WA1200-6 30-193
Electrical system
3] Using [F2], [F3], [F4], and [F5] switches,

enter the loaded weight.
[F2]: Returns the highlighted input digit.
[F3]: Decrements the highlighted numeric
value.
[F4]: Increments the highlighted numeric
value.
[F5]: Advances the highlighted input digit.
If the highlighted input digit is the tenths
place, a screen for entering the loaded
weight appears.
[F6]: The original loaded weight reap-
pears.
5) Performing loaded calibration

1] Select "Loaded calibration" shown on the
screen by pressing the [F3] or [F4] switch
and validate the selection using the
"Select" [F6] switch.
4] When the tenths place is highlighted and

the [F5] switch is then pressed, the
screen for validating the loaded weight
appears.
5] Press the [F5] switch if the entered
loaded weight is correct. To correct the
loaded weight, press the [F2] switch and
2] When the "Loaded calibration" screen
enter the loaded weight again.
appears, operate the machine by
6] When the setting is normally completed, a
following the instructions given on the
message of setting completed appears
screen.
on the screen.
When the calibration is normally
After verification, press the [F1] switch
completed, the loaded weight entry
located at the lower left corner of the
screen appears.
screen to return to the "Load meter menu"
screen.
30-194 WA1200-6
Electrical system
7] If the calibration is not normally termi- 3] When the resetting is normally

nated, a warning screen appears. Press completed, a message of resetting
the [F5] switch to return to the "Load completed appears on the screen.
meter menu" screen and start the proce- After verification, press the [F1] switch
dure over. located at the lower left corner of the
screen. The "Load meter menu" screen
reappears.
6) Reset of calibration
1] Select "Calibration reset" shown on the
screen by pressing the [F3] or [F4] switch 7) Selecting display/nondisplay of load meter
and validate the selection using the 1] Select "Load meter show/hide selection"
"Select" [F6] switch. shown on the screen by pressing the [F3]
or [F4] switch and validate the selection
using the "Select" [F6] switch.
2] To reset the calibration, press the [F5]

switch. To not reset the calibration, press
the [F2] switch. 2] Each press of the "Change" switch alter-
nates the machine monitor between
display and nondisplay.
After setting, press the [F1] switch located
at the lower left corner of the screen to
return to the "Load meter menu" screen.
WA1200-6 30-195
Electrical system
8) Setting the target for the subtraction mode

1] Select "Setting the decrement mode
target" shown on the screen by pressing
the [F3] or [F4] switch and validate the
selection using the "Select" [F6] switch.
2] Using [F2], [F3], [F4], and [F5] switches,

enter the target weight.
[F2]: Returns the highlighted input digit.
[F3]: Decrements the highlighted numeric
value.
[F4]: Increments the highlighted numeric
value.
[F5]: Advances the highlighted input digit.
If the highlighted input digit is the ones
place, a screen for entering the loaded
weight appears.
[F6]: The original loaded weight reap-
pears.
30-196 WA1200-6
Electrical system
3] When the ones place is highlighted and

the [F5] switch is then pressed, the
screen for completing the setting
appears.
4] The screen as shown on the right shows
that setting is completed.
After verification, press the [F1] switch
located at the lower left corner of the
screen to return to the "Load meter menu"
screen.
5] If the setting is abnormally terminated, a

warning screen as shown on the right
appears. Press the [F5] switch to return to
the "Load meter menu" screen and start
the procedure over.
WA1200-6 30-197
Electrical system
Service Menu 30-198

1. How to enter into the service menu
(*1) Press the [F6] switch to enter the currently

When this screen is displayed, 1 is highlighted. displayed ID. If the ID is correct, the service
Press the [F1] switch to return to the user menu screen appears.
settings screen. When it is a wrong ID, the screen remains
Each time the [F2] switch is pressed, the last unchanged.
input digit is erased. Press the [F2] switch to erase the incorrectly
If no numeral is entered, the screen does not input ID. When the correct ID is input, the service
change. menu screen appears.
Press the [F3] switch to move the highlight to the Or, press the [F1] switch to return to the user
left digit of the currently selected (highlighted) settings screen.
digit.
pressing [F3] highlights "0".
Press the [F4] switch to move the highlight to the
right digit of the currently selected (highlighted)
digit.
pressing [F4] highlights "1"
Press the [F5] switch to select the highlighted
digit. "*" is showed on the display. (Input the
value in order, starting from the leftmost digit.)
30-198 WA1200-6
Electrical system
a Two types of ID are provided: the usual ID 2. Real-time monitor

and special ID that allows for entering the When changed to this screen (Real-time monitor
special optional menu. The entry of the spe- (controller selection)), the main monitor is high-
cial ID allows you to enter the special optional lighted.
menu "Engine mode" in addition to the Press the [F3] switch to move the highlighted
menus that are allowed by entry of the usual controller downward in sequence.
ID. When the [F3] switch is pressed at the bottom
Service password: 7823401300 item, the highlight moves to the top item.
Special password: 3287040031 Press the [F4] switch to move the highlighted
(*2) controller upward in sequence.
When changed to this screen (Service Menu) When the [F4] switch is pressed at the top item,
the real-time monitor is highlighted. the highlight moves to the bottom item.
Press the [F3] switch to move the highlighted Press the [F1] switch to return to the service
menu downward in sequence. (Scroll func- menu selecting screen.
tion) Press the [F6] switch to open the real-time
When the [F3] switch is pressed at the monitor screen for the highlighted controller.
bottom item, the highlight moves to the top (For details, see specifications for the corre-
item. sponding screen.)
Press the [F4] switch to move the highlighted
menu upward in sequence. (Scroll function) REAL TIME MONITOR screen (for selection of
When the [F4] switch is pressed at the top controller)
item, the highlight moves to the bottom item.
Press the [F1] switch to return to the standard
screen.
Press the [F6] switch to open the screen for
the highlighted menu item. (For details, see
specifications for the corresponding screen.)
WA1200-6 30-199
Electrical system
Press the [F1] switch to return to the real-time As the engine has 16 cylinders, in order to check
monitor (controller selection) selecting screen. the exhaust gas temperature of 16 cylinders at
Press the [F2] switch to go to the next page. the same time, a special screen " Exhaust gas
Press the [F5] switch to go to the previous page. temperature list" is provided.
When the [F3] switch is pressed while the value If the menu of "6 ITEMS" is selected, desired
is not held, the displayed value is held. cylinders can be specified (each cylinder has an
(The button indication changes to "RESET".) ID) to check the exhaust gas temperature of indi-
When the [F3] switch is pressed while the value vidually. To check exhaust gas temperature of
is held, the held value is released. all cylinders at once, use the real time monitor
(The button indication changes to "PAUSE".) function of the engine controller.
For information on real time monitoring items of
each controller, refer to "Real time monitor
display items".
Each screen heading includes the controller

name to facilitate identification of controller that
is in charge of the current real time monitor.
Real time monitor screen (main monitor, trans-

mission controller, work equipment controller,
engine controller, and KOMTRAX Plus)
(Example of real time monitor screen of main
monitor)
When changed to this screen (Real-time monitor

(6ITEMS)), the first row is highlighted.
row downward in sequence.
When the [F3] switch is pressed at the bottom
item, the highlight moves to the top item.
row upward in sequence.
When the [F4] switch is pressed at the top item,
the highlight moves to the bottom item.
Press the [F1] switch to return to the real-time
monitor (controller selection) selecting screen.
When the [F5] switch is pressed while the value
is not held, the displayed value is held.
(The button indication changes to "RESET".)
When the [F5] switch is pressed while the value
is held, the held value is released.
Press the [F6] switch to open the ID input screen
for the highlighted row.
30-200 WA1200-6
Electrical system
6 ITEMS screen Press the [F1] switch to abort ID input and return
(ID returns to the value that was held before
change to this screen.)
input box to the previous box.
If the foremost place is highlighted, the high-
lighted place does not move.
Press the [F3] switch to change the highlighted
digit in the sequence:
"9o8o7o6o5o4o3o2o1o0o9…".
Press the [F4] switch to change the highlighted
digit in the sequence:
"1o2o3o4o5o6o7o8o9o0o1…".
input box to the next box.
If the last input place is highlighted, pressing [F5]
does not move the highlighted place.
Press the [F6] switch to validate the input ID and
return to the previous screen.
ID input screen
The data is displayed only when the ID entered

has a corresponding monitoring item.
If the ID entered has no corresponding moni-
toring item, only the ID entered is displayed.
The ID entered once is held in that place until the
starting switch is turned to OFF position or the ID
is changed.
A: When correct ID is entered

B: When wrong ID is entered
WA1200-6 30-201
Electrical system
Real time monitor display items

(*): Digits out of the display range are indicated as "-" (zeros, upper or lower limit values are not displayed).
Machine monitor
Monitor
Data Display range of data
unit (Example of display) (*)
page
1 1 20200 MONITOR PROG P/N --- 10-digit part No. is displayed.
2 1 20221 VERSION(APP) --- 01010101
3 1 20222 VERSION(DATA) --- 01010101
Source: transmission
4 2 01001 ENGINE SPEED 1 rpm 0 to 4000
controller
5 2 40012 VEHICLE SPEED 0.1 km/h 0.0 to 50.0
6 2 04202 FUEL SENSOR 1% 0 to 100
7 2 04200 FUEL SENSOR 0.01V 0.0 to 5.0
Source: engine con-
8 2 04103 COOLANT TEMP 1 °C –40 to 210
troller
9 3 04408 T/C TEMP 1 °C 24 to 131
10 3 04409 T/C TEMP 0.01 V 0.00 to 5.00
11 3 04401 HYD. OIL TEMP 1 °C 24 to 131
12 3 04404 HYD. OIL TEMP 0.01 V 0.00 to 5.00
13 3 30201 BRAKE OIL TEMP 1 °C 24 to 131
14 3 30204 BRAKE OIL TEMP 0.01 V 0.00 to 5.00
15 4 04302 ALTERNATOR R 0.1 V 0.0 to 30.0
16 4 40200 SMALL LAMP 0.1 V 0.0 to 30.0
17 5 06001 BOOM ANGLE 1 deg. -90 to 90
18 5 06003 BOOM ANGLE 0.01 V 0.00 to 5.00
19 5 40400 BOOM BOTTOM PRESSURE 0.01 MPa 0.00 to 50.00
20 5 40402 BOOM BOTTOM PRESSURE 0.01 V 0.00 to 5.00
21 5 40500 BOOM HEAD PRESSURE 0.01 MPa 0.00 to 50.00
22 5 40501 BOOM HEAD PRESSURE 0.01 V 0.00 to 5.00
23 6 40600 CAL PRESSURE 0.01 MPa 0.00 to 50.00
24 6 40800 MEASURED LOAD 0.01 t 0.00 to 50.00
25 7 40900 D-IN 0-7 --- 01010101
26 7 40901 D-IN 8-15 --- 01010101
27 7 40902 D-IN 16-23 --- 01010101
28 7 40903 D-IN 24-31 --- 01010101
29 7 40904 D-IN 32-39 --- 01010101
30 7 40925 D-OUT 0-3 --- 01010101
30-202 WA1200-6
Electrical system
KOMTRAX Plus controller

Monitor
page
1 1 37501 AMBIENT AIR TEMP 1 °C -30 to 100
2 1 37504 AMBIENT AIR TEMP 0.01 V 0.00 to 5.00
3 1 99701 PPC OIL PRESSURE 0.01 MPa 0.00 to 50.00
4 1 99700 PPC OIL PRESSURE 0.01 V 0.00 to 5.00
5 1 04304 CHARGED AMOUNT 0.1 V 0.0 to 30.0
6 2 99703 T/M MAIN PRESSURE 0.01 MPa 0.00 to 50.00
7 2 99702 T/M MAIN PRESSURE 0.01 V 0.00 to 5.00
8 2 99705 T/M LUB PRESSURE 0.01 MPa 0.00 to 50.00
9 2 99704 T/M LUB PRESSURE 0.01 V 0.00 to 5.00
10 3 32601 T/C IN PRESSURE 0.01 MPa 0.00 to 50.00
11 3 32602 T/C IN PRESSURE 0.01 V 0.00 to 5.00
12 3 32603 TC OUT PRESSURE 0.01 MPa 0.00 to 50.00
13 3 32604 TC OUT PRESSURE 0.0 1V 0.00 to 5.00
14 3 29700 S/T PUMP PRESSURE 0.01 MPa 0.00 to 50.00
15 3 29701 S/T PUMP PRESSURE 0.01 V 0.00 to 5.00
F BRAKE OIL PRES-
16 4 92800 0.01 MPa 0.00 to 50.00
SURE
F BRAKE OIL PRES-
17 4 92802 0.01 V 0.00 to 5.00
SURE
R BRAKE OIL PRES-
18 4 92801 0.01 MPa 0.00 to 50.00
SURE
R BRAKE OIL PRES-
19 4 92803 0.01 V 0.00 to 5.00
SURE
20 5 40303 BATTERY LEVEL 1 0.01 V 0.00 to 5.00
01010101 ["1" or "0" in the corre-
23 6 40944 D-IN 0-7 ---
01010101 ["1" or "0" in the corre-
24 6 40945 D-IN 8-15 ---
Outputs the input signals
ing digit (number)]
25 6 40972 D-IN 16-18 --- intact of D_IN_16 to
1: input signal ON, 0: input signal
D_IN_18
0101 ["1" or "0" in the corre-
Outputs the output signals
sponding digit (number)]
26 6 40948 D-OUT 0-3 --- intact of D_OUT_0 to
1: output signal ON, 0: output sig-
D_OUT_3
nal OFF, unused part is also zero.
0101 ["1" or "0" in the corre-
27 6 40947 D=SOL 0-3 ---
1: input signal ON, 0: input signal intact of SEL_0 to SEL_3
WA1200-6 30-203
Electrical system
Engine controller
Monitor
page
1 1 01002 ENGINE SPEED 1 rpm 0 to 8031 CM850
2 1 04102 COOLANT TEMP 1 °C -273 to 1735 CM850
3 1 42700 ENGINE OIL TEMP 1 °C –40 to 210 CM850
4 1 36400 COMMON RAIL PRESSURE 0.01 MPa 0 to 250.00 CM850
5 1 42801 BLOW BY PRESSURE 0.01 kPa -250 to 251.99 CM850
6 1 36501 BOOST PRESSURE 1 kPa 0 to 500 CM850
7 2 37200 ENGINE OIL PRESSURE 1 kPa 0 to 1000 CM850
8 2 43800 ENGINE OIL LEVEL --- OK (normal), NG (defective) CM850
9 2 37400 ATMOSPHERE PRESSURE 1 kPa 0 to 125 CM850
10 2 37300 FUEL CONSUMP 0.1 l/h 0.0 to 3212.8 CM850
11 3 – EXHAUST GUS TEMP 1 °C -273 to 1735 CM850
12 4 42614 EXHAUST GUS TEMP AVERAGE 1 °C -273 to 1735 CM850
13 4 42615 EXHAUST GUS TEMP R AVERAGE 1 °C -273 to 1735 CM850
14 4 42616 EXHAUST GUS TEMP L AVERAGE 1 °C -273 to 1735 CM850
15 5 42617 EXHAUST GUS TEMP R1 1 °C -273 to 1735 CM850
23 7 42625 EXHAUST GUS TEMP L1 1 °C -273 to 1735 CM850
a In the REAL TIME MONITOR (ENG controller), the exhaust gas temperature list screen is available
specially.
q As this screen is special, it cannot be displayed in [6 ITEMS] menu screen.
30-204 WA1200-6
Electrical system
Transmission controller
Monitor
Data Data unit
details (and range)
page
Part number of mass production 10-digit number
1 1 20201 T/M PROG P/N
software (78**-**-****)
T/M VER- Software version (software logic According to software ver-
2 1 20223
SION(APP) part version) sion
T/M VER- Software version (software data According to software ver-
3 1 20224
SION(DATA) part version) sion
0: Torque curve H For WA1200, 1:
Engine mode for engine output
4 2 41600 ENGINE MODE 1: Torque curve M Torque curve M
control
2: Torque curve L is not used.
Mod/C SPEED: x 1 [min-1]
5 2 92502 Modulation clutch output speed
OUT (0 to 32767 [min-1])
x 1 [min-1]
6 2 31400 T/M SPEED: OUT Transmission output shaft speed
(0 to 32767 [min-1])
x 1 [min-1]
7 2 93900 TIRE FR SPEED Front left tire speed
(0 to 32767 [min-1])
x 1 [min-1]
8 2 01008 ENGINE SPEED Engine speed
(0 to 32767 [min-1])
T/M CUT OFF Reduced transmission cutoff set x 0.001 [MPa]
9 3 41203
SET PRESSURE pressure (IN pressure) (0 to 5 [MPa])
T/M CUT OFF x 0.001 [MPa]
10 3 41201 Reduced brake oil pressure
PRESSURE (0 to 5 [MPa])
T/M CUT OFF x 0.001 [V]
11 3 41202 Input voltage of brake pressure
PRESSURE (0 to 5 [V])
T/C SPEED x 1 [%]
12 3 93700 Torque converter speed ratio
RATIO (0 to 100 [%])
Transmission oil temperature x 1 [ °C]
13 4 93600 T/M OIL TEMP
(A_IN_1) (0 to 150 [ °C])
Input voltage of transmission oil x 1 [mV]
14 4 93601 T/M OIL TEMP
temperature (A_IN_1) (0.00 to 5.00 [V])
Transmission oil temperature x 1 [ °C]
15 4 93602 T/M OIL TEMP2
(A_IN_3) (0 to 150 [ °C])
Input voltage of transmission oil x 1 [mV]
16 4 93603 T/M OIL TEMP2
temperature input (A_IN_3) (0.00 to 5.00 [V])
MOD/C PRES- Oil pressure equivalent to modula- x 1 [MPa]
17 4 92400
SURE tion clutch pressure input (A_IN_7) (0.00 to 5.00 [MPa])
MOD/C PRES- Voltage value of modulation clutch x 1 [mV]
18 4 92401
SURE pressure input (A_IN_7) (0.00 to 5.00 [V])
Because of
THROTTLE 0: RPM set switch OFF
LOCK A 1: PRM set switch ON
log port
0: PRM set auto-decelera-
Because of
THROTTLE tion switch OFF
LOCK B 1: PRM set auto-decelera-
log port
tion switch ON
THROTTLE LIMIT Command value for lower limit of x 0.1 [%]
21 5 44201
LO throttle position (0.0 to 100.0 [%])
x 1 [%]
22 6 94000 TRACTION DIAL Set value of traction dial
(0 to 100 [%])
Input voltage of set value from trac- x 1 [mV]
23 6 94001 TRACTION DIAL
tion dial (0.00 to 5.00 [V])
x 1 [km/h]
24 6 40014 SPEED DIAL Set value of speed control dial
(3 to 12 [km/h])
Input voltage of set value from x 1 [mV]
25 6 40015 SPEED DIAL
speed control dial (0.00 to 5.00 [V])
Current value of ECMV output x 1 [mA]
26 7 31602 ECMV 1 DIR
command to 1st clutch (0 to 1000 [mA])
27 7 31603 ECMV 2 DIR
command to 2nd clutch (0 to 1000 [mA])
28 7 31604 ECMV 3 DIR
command to 3rd clutch (0 to 1000 [mA])
29 7 31608 ECMV F DIR
command to FWD clutch (0 to 1000 [mA])
30 7 31606 ECMV R DIR
command to REV clutch (0 to 1000 [mA])
ECMV MOD/C Current value of ECMV output x 1 [mA]
31 7 31640
DIR command to modulation clutch (0 to 1000 [mA])
WA1200-6 30-205
Electrical system
Monitor
Data Data unit
details (and range)
page
Fill time of 1st clutch (at last gear x 0.01 [sec]
32 8 41802 FILL TIME 1
Fill time of 2nd clutch (at last gear x 0.01 [sec]
33 8 41803 FILL TIME 2
Fill time of 3rd clutch (at last gear x 0.01 [sec]
34 8 41804 FILL TIME 3
Fill time of FWD clutch (at last gear x 0.01 [sec]
35 8 41808 FILL TIME F
Fill time of REV clutch (at last gear x 0.01 [sec]
36 8 41806 FILL TIME R
1: ON, 0: OFF(OPEN)
1: ON, 0: OFF(OPEN)
1: ON, 0: OFF(OPEN)
1: ON, 0: OFF(OPEN)
Fix to 0 for
1: ON, 0: OFF(OPEN)
41 9 40942 D-IN 32-39 Status of input signal unused ports 33
to 39.
1: ON, 0: OFF(OPEN)
42 10 40949 D-OUT 0-7 to 7. '0' indicates that drive current
is output.
1: ON, 0: OFF(OPEN)
43 10 40950 D-OUT 8-15 to 11B. '0' indicates that drive cur-
rent is output.
to 3, SW_OUT0 to 1, and 1: ON, 0: OFF(OPEN)
44 10 40951 D-OUT 16-23
BATT_RY_OUT. '0' indicates that Corresponds to each bit
drive current is output.
11-digit number indicates
learning flags for clutches in
the following order:
[FFFRRR11123]
Learned: 1, Not learned: 0 11-bit data in
Status of trigger time initial learning F, R, and 1st clutches have 3 order of
Trigger Learning flag for each clutch flags depending on learning FFFRRR11123 is
45 11 94100
Flag conditions starting from the displayed on
[F, F, F, R, R, R, 1, 1, 1, 2, 3] left: engine speed Z 875 rpm, multi-function
875 to 1200 rpm, and monitor.
engine speed X 1200 rpm
Learning flags for 2nd and
3rd clutches do not depend
on engine speed.
ANGLE SEN- Inclination angle equivalent to pitch x 0.1 [deg]
46 11 32900
SOR(FR) angle sensor input (A_IN_9) (-25.0 to 25.0 [deg])
ANGLE SEN- Voltage value of pitch angle sensor x 1 [mV]
47 11 32902
SOR(FR) input (A_IN_9) (0.00 to 5.00 [V])
ANGLE SEN- Inclination angle equivalent to pitch x 0.1 [deg]
48 11 32904
SOR(LR) angle sensor input (A_IN_9) (-25.0 to 25.0 [deg])
ANGLE SEN- Voltage value of pitch angle sensor x 1 [mV]
49 11 32905
SOR(LR) input (A_IN_9) (0.00 to 5.00 [V])
BRAKE OIL x 1 [MPa]
PRESSURE F (0.00 to 50.00 [MPa])
(A_IN_15)
BRAKE OIL Voltage value of brake oil pressure x 1 [mV]
51 12 35504
PRESSURE F sensor input (A_IN_15) (0.00 to 5.00 [V])
BRAKE OIL x 1 [MPa]
PRESSURE R (0.00 to 50.00 [MPa])
(A_IN_16)
BRAKE OIL Voltage value of brake oil pressure x 1 [mV]
53 12 35505
PRESSURE R sensor input (A_IN_16) (0.00 to 5.00 [V])
30-206 WA1200-6
Electrical system
Monitor
Data Data unit
details (and range)
page
Part number of mass produc- 10-digit number
1 1 20202 BBC PROG P/N
tion software (78**-**-****)
2 1 20225 BBC VERSION (APP)
logic part version) sion
3 1 20226 BBC VERSION (DATA)
data part version) sion
Command current value to lift x 1 [mA]
arm RAISE EPC (0 to 1000 [mA])
arm RAISE EPC (0 to 1000 [mA])
arm LOWER EPC (0 to 1000 [mA])
arm LOWER EPC (0 to 1000 [mA])
Command current value to x 1 [mA]
bucket TILT EPC (0 to 1000 [mA])
bucket TILT EPC (0 to 1000 [mA])
bucket DUMP EPC (0 to 1000 [mA])
bucket DUMP EPC (0 to 1000 [mA])
Input voltage value from lift x 0.001 [V]
12 4 42000 BOOM POT1
arm lever potentiometer 1 (0.00 to 5.00 [V])
Input voltage value from lift x 0.001 [V]
13 4 42001 BOOM POT2
arm lever potentiometer 2 (0.00 to 5.00 [V])
Input voltage value from x 0.001 [V]
bucket lever potentiometer 1 (0.00 to 5.00 [V])
Input voltage value from x 0.001 [V]
bucket lever potentiometer 2 (0.00 to 5.00 [V])
x 0.1 [deg]
16 5 06002 BOOM ANGLE Calculated lift arm angle
(-60.0 to +60.0 [deg])
Input voltage value from lift
x 0.001 [V]
17 5 06005 BOOM ANGLE arm angle sensor potentiome-
(0.00 to 5.00 [V])
ter
The number of lift arm lever
18 5 42100 BOOM LEVER operations expressed in incre-
of 1000 operations)
The number of bucket lever
19 5 42101 BUCKET LEVER operations expressed in incre-
of 1000 operations)
x 1 [cc/rev]
20 5 94600 PUMP FLOW Calculated pump delivery
(150 to 830 [cc/rev])
AJSS lever angle equivalent
x 0.1 [deg]
21 6 94300 AJSS LEVER to AJSS lever potentiometer
(-60.0 to +60.0 [deg])
input
Input voltage value from AJSS x 0.001 [V]
lever potentiometer (0.00 to 5.00 [V])
Frame angle equivalent to
x 0.1 [deg]
23 6 94400 FRAME ANGLE AJSS frame potentiometer
(-60.0 to +60.0 [deg])
input
Input voltage value from AJSS x 0.001 [V]
24 6 94401 FRAME ANGLE
frame potentiometer (0.00 to 5.00 [V])
Command current to AJSS x 1 [mA]
25 6 41908 AJSS EPC DIR
EPC (0 to 1000 [mA])
Reduced loader pump pres- x 0.01 [MPa]
sure (0 to 56.3 [MPa])
Input voltage value of loader x 0.001 [V]
pump pressure (0 to 5 [V])
BOOM BOTTOM Reduced lift arm cylinder bot- x 0.01 [MPa]
28 7 40401
PRESSURE tom pressure (0 to 50 [MPa])
BOOM BOTTOM Input voltage value of lift arm x 0.001 [V]
29 7 40402
PRESSURE cylinder bottom pressure. (0 to 5 [V])
Deviation between AJSS
x 0.1 [deg]
30 7 94800 S/T DEFLECTION frame potentiometer angle
(0.0 to +120.0 [deg])
and AJSS lever angle
WA1200-6 30-207
Electrical system
Monitor
Data Data unit
details (and range)
page
Status of digging-in-progress 1: ON (when in digging
31 7 94900 WORK FLAG
flag operation), 0: OFF
1: ON, 0: OFF(OPEN)
Applied to each bit
1: ON, 0: OFF(OPEN)
Applied to each bit
1: ON, 0: OFF(OPEN)
Applied to each bit
1: ON, 0: OFF(OPEN)
Applied to each bit
Input signals 33-39
without port are
1: ON, 0: OFF(OPEN)
36 8 40961 D-IN 32-39 Status of input signal fixed at 0 to sim-
Applied to each bit
plify communica-
tion information.
ON/OFF output from
SOL_OUT0 to 7. 1: ON, 0: OFF(OPEN)
37 9 40952 D-OUT 0-7
'0' indicates that drive current Applied to each bit
is output.
ON/OFF output from
SOL_OUT8 to 11B. 1: ON, 0: OFF(OPEN)
38 9 40953 D-OUT 8-15
'0' indicates that drive current Applied to each bit
is output.
ON/OFF output from
SIG_OUT2 to 3, HSW_OUT0
1: ON, 0: OFF(OPEN)
39 9 40954 D-OUT 16-23 to 1, and BATT_RY_OUT
Applied to each bit
'0' indicates that drive current
is output.
30-208 WA1200-6
Electrical system
3. Pm Clinic function 1) Pm Clinic menu

The machine monitor uses signals from the The Pm Clinic display is accessed through
sensors installed at different parts of the service menu selection, showing the engine
machine to permit Pm Clinic function that checks speed and oil pressures at different parts of
the engine speed and oil pressures at different the machine.
parts of the machine. 1] Pm Clinic item screen (1/4)
The monitor also has a function of retaining the Displays the engine speed, oil pressure,
fluctuation data, as in the real-time monitor. oil quantity, and coolant temperature.
a When the [F6] switch is pressed with the ser-
vice ID input, the service menu selecting
screen appears.
a The Pm Clinic screen is changed in

the same manner as with the real-time
monitor and the description for it is
q Select Pm Clinic by pressing [F3] or [F4]. omitted.
q Press the [F6] switch to move to the Pm Clin-
ic menu screen. 2] Pm Clinic item screen (2/4)
q Press the [F1] switch to return to the date set- Displays are information on the engine
ting top screen. speed, blow-by pressure, boost pressure,
exhaust gas temperature, atmospheric
temperature, and fuel rail pressure.
WA1200-6 30-209
Electrical system
3] Pm Clinic item screen (3/4) 2) Details of Pm Clinic display flow

Displays the information on the torque
converter oil temperature, inlet pressure,
outlet pressure, transmission main pres-
sure, lubricating pressure, and MOD
(modulation) pressure.
4] Pm Clinic item screen (4/4)

Displays the information on, for example,
the hydraulic oil temperature, PPC oil
pressure, hydraulic oil pressure, steering
pump pressure, front frame oil pressure,
and rear brake oil pressure.
30-210 WA1200-6
Electrical system
4. Abnormality record display function q Press the [F6] switch on a failure item
The machine monitor records failure that to put it in nondisplay mode.
occurred in the past or that are occurring at Once put in the nondisplay mode, the
present. record for this item will not be
a When the [F6] switch is pressed with the ser- displayed again.
vice ID input, the "SERVICE MENU SE- (However, the KOMTRAX Plus
LECT" screen appears. controller memory will be kept.)
q Select the abnormality record ("Failure Histo-

ry") with [F3] or [F4].
q Press the [F6] switch to move to the abnor-
mality record screen.
turns to the date setting screen.
1) Abnormality record display
The abnormality record displays such infor-
mation as the failure code, details of the
failure, the number of times the failure
occurred, time and date when the failure
occurred for the first time, and time and date
when the latest failure occurred, in reverse
chronological order.
1] Abnormality record display screen
q Scroll the item with [F3] or [F4].

q Skip over three items to display every
fourth one with [F2] or [F5].
q If the [F1] switch is pressed, the
screen returns to the service menu se-
lect screen.
WA1200-6 30-211
Electrical system
2] Information displayed on "Abnormality 5. Snapshot function

Record" screen The snapshot function can store data in the
The abnormality record display screen KOMTRAX Plus controller for use in Pm Clinic,
shows failure information on the screen and inspection and adjustments.
as follows. a When the [F6] switch is pressed with the ser-
(a): Failure occurring in reverse chrono- vice ID input, the service menu selecting
logical order screen appears.
(b): Failure code
(c): Detail of failure
(d): Number of times the failure occurred
(e): Time and date of occurrence
(e): Time and date of latest recovery
a For all the failure codes that the ma-
chine monitor can record, see Trou-
bleshooting, "Fault code list".
2) Abnormality record menu

a For the procedure to erase the abnormal-
ity record, see 7. Memory clear function.
q Select the Snapshot Trigger with [F3] or [F4].

q Press the [F6] switch to move to the snap
shot screen.
q Press the [F1] switch to return to the date set-
ting top screen.
1) Snapshot menu
The Snapshot function stores data including
engine speed and oil pressures in the
KOMTRAX Plus controller.
1] Snapshot display screen (1/6)
q Press the [F6] switch to move to the

next Snapshot screen (2/6).
lecting screen.
30-212 WA1200-6
Electrical system
2] Snapshot display screen (2/6) 4] Snapshot display screen (4/6)

The screen prompts you to determine Snapshot is performed with a message of
whether the Snapshot is to be started or Snapshot being run and the elapsed time
not. appearing on the screen.
q Press the [F5] switch to move to the q Pressing the [F1] switch stops the
Snapshot starting screen. Snapshot, showing the Snapshot
q If the [F2] switch is pressed, the screen 6].
screen returns to the previous screen.
5] Snapshot display screen (5/6)
3] Snapshot display screen (3/6) The snapshot ending screen appears.
Performance of Snapshot is started with a
message of Snapshot being run and the
elapsed time appearing on the screen.
a End of Snapshot
screen returns to the Snapshot screen
q Pressing the [F1] switch stops the 2].
Snapshot, showing the Snapshot q If the [F1] switch is pressed, the
screen 1]. screen returns to the service menu se-
lecting screen.
WA1200-6 30-213
Electrical system
6] Snapshot display screen (6/6) 6. Adjustment Menu

Snapshot cancel display screen 1) Adjustment menu selecting screen
When this screen (adjustment screen)
appears,
the Load Meter is highlighted.
menu downward in sequence.
menu upward in sequence.
Press the [F1] switch to return to the service
menu selecting screen.
Press the [F6] switch to open the screen for
the highlighted menu item.
a End of Snapshot cancellation

screen returns to the Snapshot screen
2].
lecting screen.
2) Details of Snapshot menu flow
2) Adjustment Menu (1) Load Meter

1] When this screen (Adjustment screen)
appears,
the boom angle sensor (upper) adjust-
ment is highlighted.
Press the [F3] switch to move the high-
lighted menu downward in sequence.
lighted menu upward in sequence.
Press the [F1] switch to return to the
Adjustment screen.
Press the [F6] switch to open the screen
for the highlighted menu item.
30-214 WA1200-6
Electrical system
2] Boom angle sensor (upper) adjustment Operate the machine according to the
screen instructions given by the screen message
Operate the machine according to the and press the [F6] switch.
instructions given by the screen message Press the [F6] switch to send a set signal
and press the [F6] switch. to the main monitor.
Press the [F6] switch to send a set signal A message appears according to the
to the main monitor. command (setting completed or setting
A message appears according to the failed) from the main monitor.
command (setting completed or setting When the setting is completed: Finished
failed) from the main monitor. When the setting failed: Wrong Value
When the setting is completed: Finished Until a command is received: Setting is
When the setting failed: Wrong Value underway
Until a command is received: Setting is
underway
Adjustment (1) load meter screen.
4] Payload setting screen

Select payload setting on the Adjustment
(1) load meter screen and press the [F6]
switch.
3] Boom angle sensor (lower) adjustment
screen
Press the [F3] switch to select boom
angle sensor (lower) adjustment and
press the [F6] switch.
When this screen (payload setting)

appears,
the current payload setting value is
shown.
The current setting value complies with
the information from the main monitor and
"---" appears until one is sent from the
main monitor.
If the current setting value is not received
from the main monitor for 10 seconds or
more, an abnormal end screen appears.
Press the [F3] switch to decrement the
value by 1[t].
WA1200-6 30-215
Electrical system
Press the [F4] switch to increment the The main monitor issues a command to
value by 1[t]. show this screen at an abnormal end, but
q Threshold setting range once the screen appears, control is
Metric tons: 20 to 99 [t] passed onto the multi monitor
US tons: 22 to 99 [t] (KOMTRAX Plus).
If 99 [t] is specified in metric tons or US After the message is confirmed, press the
tons, a special mode is set in which no [F5] switch to go to the Adjustment (1)
alarm is issued for any payload. load meter screen.
q When the metric tons or US tons is
changed, the previous setting value is
stored in memory and a value is dis-
played corresponding to the set ton-
nage.
Press the [F6] switch to validate the
currently displayed payload setting value
and notify it to the main monitor.
If the main monitor receives a change, the
screen returns to the adjustment (1) load
meter screen.
If no acknowledgement is received from

the main monitor for 10 seconds or more
after notification of the validation to the
main monitor, an abnormal end screen
appears.
Note, however, that no operation is
acceptable until the main monitor sends
the setting (while "---" is being displayed).
If the [F1] switch is pressed, the setting is
aborted and the Adjustment (1) load
meter screen reappears.
30-216 WA1200-6
Electrical system
If a communication failure with the

controller lasts for 0.5 seconds or more
during adjustment, the screen returns to
the service menu screen without showing
the abnormal end screen.
2] AJSS neutral position adjustment screen

Operate the machine according to the
instructions given by the screen message
and press the [F6] switch.
Press the [F6] switch to send a set signal
3) Adjustment (AJSS) to the work equipment controller.
1] Adjustment Menu (2) AJSS screen A message appears according to the
Select AJSS on the Adjustment screen command (setting completed or setting
and press the [F6] switch. failed) from the work equipment
controller.
When the setting is completed: Finished
When the setting failed: Wrong Value
underway
Adjustment (2) AJSS screen.
When this screen (Adjustment screen)

appears,
the AJSS neutral position adjustment is
highlighted.
lighted menu downward in sequence.
lighted menu upward in sequence.
Adjustment screen.
WA1200-6 30-217
Electrical system
3] AJSS EPC output current adjustment A change of the numeric value is

screen displayed according to the work equip-
When this screen appears, the adjustment controller. The multi monitor is not
ment current value is displayed according concerned with changes in the numeric
to the information from the work equip- value through button operations.
ment controller.
"---" is displayed until information is noti-
fied for the first time after the screen
appears.
Press the [F3] switch to send an UP
signal to the work equipment controller.
After the transmission of the signal, the
adjustment current value is updated
according to a signal from the work equip-
ment controller.
A change of the numeric value is
displayed according to the work equip-
ment controller. The multi monitor is not
concerned with changes in the numeric
value through button operations.
5] AJSS-related setting abnormal end
confirm screen
The main monitor issues a command to
show this screen at an abnormal end, but
ment controller.
once the screen appears, control is
passed onto the multi monitor
(KOMTRAX Plus).
After the message is confirmed, press the
[F5] switch to go to the Adjustment (2)
AJSS screen.
controller lasts for 0.5 seconds or more
the service menu screen without
displaying the abnormal end screen.
4] AJSS oil pressure command table pattern

change ("AJSS Oil Pres Comd Table
Pattern Chg.") Table screen
When this screen appears, the table
pattern number is displayed according to
the information from the work equipment
controller.
"-" is displayed until information is notified
for the first time after the screen appears.
Press the [F6] switch to send an AJSS oil
pressure command table pattern change
pattern number is updated according to a
signal from the work equipment
controller.
30-218 WA1200-6
Electrical system
4) Adjustment (work equipment)

1] Adjustment Menu (3) Work Equipment
screen
Select work equipment on the Adjustment
screen and press the [F6] switch.
2] Boom angle sensor (upper) adjustment

(for work equipment controller) screen
When this screen (Adjustment screen) Press the [F6] switch to send a set signal
appears, to the work equipment controller.
the boom angle sensor (upper) adjust- A message appears according to the
ment (work equipment controller) is high- command (setting completed or setting
lighted. failed) from the work equipment
Press the [F3] switch to move the high- controller.
lighted menu downward in sequence. When the setting is completed: Finished
(Scroll function) When the setting failed: Wrong Value
Press the [F4] switch to move the high- Until a command is received: Setting is
lighted menu upward in sequence. (Scroll underway
function)
Adjustment screen.
WA1200-6 30-219
Electrical system
3] Boom Raise Lever/ EPC Dead Band Two types of adjustments are available
Adjustment screen from this screen: the work equipment
Operate the machine according to the controller determines which type to use
instructions given by the screen message according to the engine speed.
and press the [F6] switch. (Multi monitor is not concerned with this)
to the work equipment controller.
A message appears according to the
command (setting completed or setting
failed) from the work equipment
controller.
underway
[Special notes]
Two types of adjustments are available
from this screen: the work equipment
controller determines which type to use
according to the engine speed.
(Multi monitor is not concerned with this)
Adjustment item
q Boom lever raise detent position ad-
justment
q Boom raise EPC current adjustment
4] Boom Lower Lever/ EPC Dead Band

Adjustment screen
controller.
underway
[Special notes]
30-220 WA1200-6
Electrical system
Adjustment item 6] Bucket Dump Lever/ EPC Dead Band

q Boom lever lower detent position ad- Adjustment screen
justment Operate the machine according to the
q Boom lower EPC current adjustment instructions given by the screen message
controller.
underway
[Special notes]
One type of adjustment is available from
this screen.
Adjustment item
5] Bucket Tilt Lever/ EPC Dead Band
q Bucket dump EPC current adjustment
Adjustment screen
controller.
underway
[Special notes]
Two types of adjustments are available 7] Boom Lever Pattern Change screen
from this screen: the work equipment When this screen appears, the table
controller determines which type to use pattern number is displayed according to
according to the engine speed. the
(Multi monitor is not concerned with this) information from the work equipment
Adjustment item controller.
q Bucket tilt detent position adjustment "-" is displayed until information is notified
q Bucket tilt EPC current adjustment for the first time after the screen appears.
Press the [F6] switch to send a boom
lever pattern change signal to the work
controller.
WA1200-6 30-221
Electrical system
9] Boom lower stop modulation adjustment

screen
When this screen appears, a numeric
value (%) is displayed according to the
information from the work equipment
controller.
"---" is displayed until information is noti-
fied for the first time after the screen
appears.
Press the [F3] switch to send an UP
ment controller.
8] Bucket Lever Pattern Change screen
When this screen appears, the table
pattern number is displayed according to
the
information from the work equipment
controller.
Press the [F4] switch to send a DOWN
"-" is displayed until information is notified
for the first time after the screen appears.
Press the [F6] switch to send a bucket
numeric value (%) is updated according
lever pattern change signal to the work
to a signal from the work equipment
controller.
controller.
30-222 WA1200-6
Electrical system
10] Work equipment-related setting abnormal

end confirm screen
The main monitor issues a command to
show this screen at an abnormal end, but
once the screen appears, control is
passed onto the multi monitor
(KOMTRAX Plus).
controller lasts for 0.5 second or more
WA1200-6 30-223
Electrical system
5) Adjustment (T/M controller) 3] T/M trigger initial learning data reset

1] Adjustment Menu (4) T/M screen screen (setting completed screen)
When this screen (Adjustment screen) A message appears according to the
appears, command (finished or wrong value) from
the T/M trigger initial learning data reset is the T/M controller.
highlighted. When the setting is completed: Finished
Press the [F1] switch to return to the When the setting failed: Wrong Value
Adjustment screen. Until a command is received: Setting is
Press the [F6] switch to open the screen underway
4] TM-related setting abnormal end confirm

2] T/M trigger initial learning data reset screen
screen The main monitor issues a command to
Press the [F2] switch to return to the show this screen at an abnormal end, but
Adjustment (4) T/M screen without reset- once the screen appears, control is
ting the data. passed onto the multi monitor
Press the [F5] switch to send a reset (KOMTRAX Plus).
signal to the T/M controller and the setting After the message is confirmed, press the
completed screen will be displayed. [F5] switch to go to the Adjustment (4) TM
A reset condition is checked with the screen.
real-time monitor. If a communication failure with the
controller lasts for 0.5 second or more
30-224 WA1200-6
Electrical system
7. Option setting screen (1/2) Option setting screen (2/2)

When this screen (option setting screen)
appears,
the boom specifications are highlighted.
Display is given according to the selected state
and information from the main monitor. (The
main monitor stores states of all options in
memory.)
item downward in sequence.
Press the [F6] switch to change the option state
of the currently highlighted item. (The option
state is sent to the network upon change.)
The main monitor stores all options selected in
memory for detection of mismatch of option
Default Choices
selection. Boom specifica-
Press the [F2] switch to change option setting STD Hi Lift Ext Hi Lift
tion
pages. Types of tire STD OPT 1 OPT 2
Tire size correc-
0% ±12%(2% increments)
tion
Economy indica-
ADD NO ADD
tion lamp
Triple prohibited NO ADD ADD
Wall surface dig-
ADD NO ADD
ging prevention
Tire slip
ADD NO ADD
prevention control
Dump approach
ADD NO ADD
control
Travel speed con-
TYPE 1 TYPE 2
trol
Engine mode AUTO P fixed E fixed
* The engine mode appears only if a special ID
is entered during entry of the service ID.
WA1200-6 30-225
Electrical system
8. Maintenance monitor function q Select the maintenance item with [F3]

The maintenance monitor function displays the or [F4] switch.
remainder time relative to a specified value for q Change pages with [F2] or [F5] switch.
each replacement time of filters and oils of q Press the [F6] switch to move to the
different types according to the maintenance maintenance monitor setting screen.
item. (Input the maintenance interval.)
Input of maintenance ID permits changing of the q If the [F1] switch is pressed, the
interval time. screen returns to the service menu.
a When the [F6] switch is pressed with the ser-
vice ID input, the service menu selecting 2] 1000 h maintenance screen
screen appears. Displays the maintenance 1000 h items.
q Select the maintenance monitor with [F3] or a The maintenance item screen is
[F4]. changed in the same manner and the
q Press the [F6] switch to move to the mainte- description for it will be omitted.
nance monitor screen.
q Press the [F1] switch to return to the date set- 3] 2000 h maintenance screen (1/2)
ting top screen. Displays the maintenance 2000 h items.
1) Maintenance monitor menu

The maintenance monitor is accessed
through service menu selection, showing the
remainder time and specified replacement
time according to the type of filter or oil.
1] The 250 h/500 h maintenance screen
shows the maintenance 250 h/500 h
items.
30-226 WA1200-6
Electrical system
4] 2000 h maintenance screen (2/2) 2) Details of the maintenance monitor display

Displays the maintenance 2000 h items. flow
5] Maintenance monitor setting screen

On the maintenance monitor setting
screen, input of the maintenance interval
time allows the interval time to be
changed.
q Press the [F3] or [F4] switch to move

to the "numeric value" to be input.
q If the [F5] switch is pressed, the se-
lected numeric value is input.
a Repeat these steps to input the nu-
merals for the maintenance monitor
setting.
q Press the [F6] switch to enter the
maintenance monitor setting time.
q Press the [F1] switch to move to the *1: Returns to the item screen from which the
item screen from which the mainte- maintenance monitor setting screen was
nance monitor setting screen was ac- accessed.
cessed.
WA1200-6 30-227
Electrical system
9. Setting the unit 3) Details of unit setting flow

To set the unit, select unit on the service menu
selecting screen.
1) To show the unit setting screen, select "Unite
Setting" with [F3] or [F4] on the service menu
selecting screen.
q Press the [F6] switch to move to the unit

selecting screen.
2) Selecting unit
Set the unit by selecting and entering one on
this screen.
q Select "SI" with [F3] or [F4].

q If the [F6] switch is pressed, the unit se-
lected is entering and the screen returns
to the service menu selecting screen.
q If the [F1] switch is pressed, the change
made is canceled and the screen returns
to the service menu selecting screen.
30-228 WA1200-6
Electrical system
10. Memory clear function q Press the [F3] or [F4] switch to move
The memory clear function erases data stored in to the "numeric value" to be input.
the KOMTRAX Plus, including the abnormality q If the [F5] switch is pressed, the se-
record, maintenance, trend, load map, and lected numeric value is input.
Snapshot. a Repeat these steps to input the mem-
a When the [F6] switch is pressed with the ser- ory clear ID.
vice ID input, the "SERVICE MENU SE- q Press the [F6] switch to enter the
LECT" screen appears. memory clear ID, showing the memo-
ry clear item screen.
2] Memory clear screen (showing items)

On the memory clear screen, select and
set the item and move to the memory
clear performance screen.
q Select memory clear with [F3] or [F4].

q Press the [F6] switch to move to the memory
clear ID entry screen.
turns to the date setting screen.
1) Memory clear menu 1 q Press the [F3] switch to move to the

The memory clear function allows each indi- memory clear maintenance item.
vidual type of data stored in the KOMTRAX q Press the [F4] switch to move to the
Plus, including the abnormality record, main- memory clear Snapshot item.
tenance, trend, load map, and Snapshot, to q If the [F1] switch is pressed, the
be erased individually from the memory with screen returns to the service menu se-
the entry of the memory clear ID. lecting screen.
1] Memory clear ID entry screen 3] Memory clear screen (showing items)

Screen on which the memory clear ID is
entered to move to the corresponding
item
q Select the memory clear item with [F3]

or [F4].
lecting screen.
WA1200-6 30-229
Electrical system
2) Memory clear menu 2 q If the [F5] switch is pressed, the abnor-

To erase data from memory, move through mality record is erased and the screen re-
items with the [F3] or [F4] switch on the turns to the memory clear screen.
memory clear screen, and select the item to
be erased with the [F6] switch, thereby 2]-1 Maintenance memory clear
displaying the memory clear screen. Select maintenance with [F3] or [F4] on
1] Abnormality record memory ("Failure the maintenance clear screen.
History Data") clear
2] Maintenance memory clear
3] Trend memory clear
4] Load map memory clear
5] Snapshot memory clear
a Press the [F6] switch with the memory clear
ID input to move to the memory clear screen.
1]-1 Abnormality record memory clear
q Press the [F6] switch to move to the mainte-

nance memory clear confirm screen.
2]-2 Maintenance memory clear confirm screen

This screen prompts you to determine
whether to erase maintenance or not.
Confirm erasure with the [F2] or [F5] switch.
q Select memory clear item abnormality re-

cord with [F3] or [F4].
q Press the [F6] switch to move to the ab-
normality record erase confirm screen.
1]-2 Abnormality record memory clear

confirm screen
whether to erase the abnormality record or
not. Confirm erasure with the [F2] or [F5]
switch.
q If the [F5] switch is pressed, the maintenance

memory is erased and the screen returns to
the memory clear screen.
q If the [F2] switch is pressed, that mainte-
nance memory is not erased and the screen
returns to the memory clear screen.
30-230 WA1200-6
Electrical system
3]-1 Trend memory clear 4]-1 Load map memory clear

Select trend with [F3] or [F4] on the memory Select the load map with [F3] or [F4] on the
clear screen. memory clear screen.
q Press the [F6] switch to move to the trend q Press the [F6] switch to move to the load map
memory clear screen. memory clear confirm screen.
3]-2 Trend memory clear confirm screen 4]-2 Load map memory clear confirm screen
This screen prompts you to determine This screen prompts you to determine
whether to erase trend memory or not. whether to clear load map memory or not.
Confirm erasure with the [F2] or [F5] switch. Confirm erasure with the [F2] or [F5] switch.
q If the [F5] switch is pressed, the trend mem- q If the [F5] switch is pressed, the load map
ory is erased and the screen returns to the memory is erased and the screen returns to
memory clear screen. the memory clear screen.
q If the [F2] switch is pressed, that trend mem- q If the [F2] switch is pressed, the load map
ory is not erased and the screen returns to memory is not erased and the screen returns
the memory clear screen. to the memory clear screen.
WA1200-6 30-231
Electrical system
5]-1 Snap shot memory clear

Select the snap shot with [F3] or [F4] on the
memory clear screen.
q Press the [F6] switch to move to the snap

shot memory clear confirm screen.
5]-2 Snap shot clear confirm screen

whether to erase snap shot memory or not.
Confirm erasure with the [F2] or [F5] switch.
q If the [F5] switch is pressed, the snap shot

memory is erased and the screen returns to
q If the [F2] switch is pressed, the snap shot
memory is not erased and the screen returns
to the memory clear screen.
30-232 WA1200-6
Electrical system
2) Details of memory clear menu flow
WA1200-6 30-233
Electrical system
11. Serial/GCC number setting function Caution and warning display function during op-
The serial/GCC number setting function allows eration 30-234
machine serial number and other information to The function displays machine failure information on
be displayed on the monitor. the monitor screen during operation as a caution or
a When the [F6] switch is pressed with the ser- warning.
vice ID entered, the service menu selecting a If a failure occurs in the machine during opera-
screen appears. tion on the standard screen (normal screen or
load meter screen), the standard screen and
warning screen alternates (every 5 seconds).
a If two or more failure occur at the same time, the
screen display changes as follows: standard
screen o warning 1 o warning 2 o standard
screen.
a For details of cautions and warnings during op-
eration, see "Instruction manual".
1. A message appears on the monitor screen.

A specific message appears on the monitor
screen.
1) Caution message display screen (example 1)
If the air cleaner is clogged, a yellow caution
appears on the monitor screen.
q Select the Serial/GCC No. Setting with [F3]
or [F4].
q Press the [F6] switch to move to the seri-
al/GCC number setting display screen.
1) Serial/GCC number setting display screen

The serial/GCC number setting display
screen shows such information as the model,
serial number, engine model, serial number,
transmission serial number, and GCC.
2) Warning message display screen (example

2)
If the torque converter oil temperature rises,
a red warning appears on the monitor
screen.
q If the [F1] switch is pressed, the service

menu selecting screen reappears.
a No serial number input screen is available
from the multi monitor.
q Press the [F1] or [F4] switch to return to warning screen.

the screen that was displayed before the
30-234 WA1200-6
Electrical system

warning screen is displayed again 2 min-
utes later.
warning is cleared (however, the
KOMTRAX Plus memory is kept).
warning display is held. When the [F3]
switch is pressed again, the screen will be
automatically switched.
WA1200-6 30-235
Pm Clinic
Outline of measurement procedure for Pm Clinic
Pm Clinic 30-236
Outline of measurement procedure for Pm Clinic 30-236
The following three ways are available for the ma- 3. Measurement procedure by downloading
surement procedure for PM clinic of WA1200-6. data in KOMTRAX Plus controller
a Basically, apply measurement procedure 1 or 2. Connect a personal computer to the KOMTRAX
1. Measurement procedure by multi monitor Plus controller and perform the quick Pm Clinic
Read the data from the Pm clinic screen by using with the multi monitor, and then download the
"Pm Clinic function" of the multi monitor. Pm Clinic data to the personal computer.
a The following tools are necessary to this
measurement procedure.
799-608-3211 CD-ROM
1
799-608-3220 Wiring harness
ZB
Commercially Note type PC
2
available (OS: Windows98/2000/Me/XP)
2. Measurement procedure by stopwatch,

scale, etc.
Take each measurement by using a stopwatch,
scale, etc.
30-236 WA1200-6
Pm Clinic
Preparation for measurement for Pm Clinic
Preparation for measurement for Pm Clinic 30-237
k For safety reasons, park the machine on a

level ground, and chock the wheels to pre-
1. Check the safety around the machine and start

the engine.
2. Warm up the engine to increase the engine

coolant temperature and hydraulic oil tempera-
ture.
q Coolant temperature: Min. 40 °C
q Hydraulic oil temperature: Min. 40 °C
3. Set the multi monitor to display the service menu

selection screen, and then select the " Pm Clinic"
menu and display " Pm Clinic (1/4)" screen.
4. Lower the work equipment to the ground and

stop the engine.
a Perform measurements using Pm Clinic ser-
vicing procedures and conditions.
WA1200-6 30-237
Pm Clinic
Pm clinic service
Pm clinic service 30-238

User name Location Date of delivery
Year Month Day
/ /
User name Machine serial No. Engine serial No.
Specifications
Tire: Front/Rear Bucket
T 55.5/80-57-68PR(L5) m3 (cu.yd)
T 66/65-57-62PR(L5) T 20.9(25.9)
T T
Type of work
Quarry, mine Construction
T Coal T Construction, civil engineering
T Gold T Roads
T Limestone T Others
T Others
Type of soil
Specific gravity: t/m3
Rock
T Gravel
T Soft
T Sand
T Ordinary
T Clay soil
T Hard
T Coal
Kind of operation
T V-shape loading Special notes
T Cross drive loading
T Load and carry
Scheduled working hour
Replacement/day Hour/replacement
T1T2T3 h
Distributor's name
30-238 WA1200-6
Pm Clinic
Pm clinic service
WA1200-6 Machine serial No.

(CUMMINS)
SSDA16V Engine serial No.
hour testing 160E-2
Work order No. Date of inspection Service meter reading Examiner
Questions asked to operator, walk around

Pass Fail
inspection
Was there any abnormality before inspection started?
Max. level of coolant temperature Max. level of torque converter oil tem- Ambient tem- °C
perature perature °C
Max. m
Min.
Height above
sea level
Inspection items
Measure-
Standard value
Item Conditions Unit Repair limit ment Pass Fail
for new machine
results
E mode 625 to 675 575 to 725
Engine: Low idle
P mode 625 to 675 575 to 725
E mode 1,850 to 1,950 1,800 to 2,000
Engine: High idle
P mode 1,850 to 1,950 1,800 to 2,000
1-1 Torque converter stall E mode rpm 1,750 to 1,950 1,650 to 2,000
Engine speed speed Pmode 1,800 to 2,000 1,700 to 2,000
Emode 1,750 to 1,950 1,650 to 2,000
Hydraulic stall
P mode 1,800 to 2,000 1,700 to 2,000
1 Engine
E mode 1,600 to 1,950 1,500 to 2,000

Full stall
P mode 1,650 to 2,000 1,550 to 2,000
1-2 kPa Max. 1.25
Torque converter stall speed 3.29 {330}
Blow-by pressure <mmH20 {Max. 127}
0.34 to 0.48 0.34
1-3 Torque converter stall speed MPa {3.5 to 4.9} {3.5}
Engine lubricating oil
Low idle <kg/cm2> Min. 0.14 0.137
pressure (SAE15W-40)
{Min. 1.43} {Min. 1.4}
1-4 kPa 150.5 to 180.5 130
Torque converter stall speed
Boost pressure <mmHg> {1,180 to 1,406} {1,000}
2-1
Min. 1.22 Min. 1.22
Torque converter inlet
Engine: At high idle Torque con- {Max. 13} {Max. 13}
pressure MPa
2 T/C
verter oil pressure: 60 to 80 °C

2-2
Transmission: Neutral <kg/cm2> 0.88 ± 0.1 0.88 ± 0.1
Torque converter outlet
{9 ± 1} { 9 ± 1}
pressure
3-1 2.7 ± 0.15 2.7 ± 0.15

Main relief pressure {28 ± 1.5} {28 ± 1.5}
3-2 Directional selec- 0.05 to 0.16 0.05 to 0.16
Lubricating oil pressure tor switch: Neu- {0.5 to 2.7} {0.5 to 2.7}
3-3 tral
2.30 to 2.60 2.30 to 2.60
Modulation clutch oil
{2.35 to 26.5} {2.35 to 26.5}
pressure
Engine: High
3 Transmission
Directional selec-
3-4 idle
tor switch: Neu- 2.45 ± 0.15 2.45 ± 0.15
1st speed clutch Torque con- MPa
tral {25 ± 1.5} {25 ± 1.5}
modulating pressure
Gear speed: 1st
verter oil tem- <kg/cm2>
perature: 60 to
Directional selec-
3-5 80 °C
tor switch: Neu- 2.45 ± 0.15 2.45 ± 0.15
2nd speed clutch modu-
tral {25 ± 1.5} {25 ± 1.5}
lating pressure
Gear speed: 2nd
Directional selec-
3-6
tor switch: Neu- 2.45 ± 0.15 2.45 ± 0.15
3rd speed clutch modu-
tral {25 ± 1.5} {25 ± 1.5}
lating pressure
Gear speed: 3rd
WA1200-6 30-239
Pm Clinic
Pm clinic service
Mea-
Standard value sure-
Item Conditions Unit Repair limit Pass Fail
for new machine ment
results
Engine: At high idle 31.36 31.36
MPa
4 Steering relief pressure Hydraulic oil temperature: 45 (+0.98/-0.29) (+0.98/-1.29)
to 55°C {kg/cm2}
320 (+18/-3) 320 (+10/-13)
4 S/T
Left lock to Engine: At

Hydraulic oil Max. 6.5 Max. 7.5
Steering right lock low idle
temperature: Sec.
time (right lock to Engine: At
45 to 55 °C Max. 5.6 Max. 6.5
left lock) high idle
5-1
Machine must be stationary
Parking brake
Front right 0 Max. 7.0
5-2 Wear of Front left 0 Max. 7.0
mm
Wheel brake brake disc Rear right 0 Max. 7.0
5 Brakes
Rear left 0 Max. 7.0

Charge:
Engine: At low 17.6 (+0.59/0) 17.6 (+0.59/0)
Cut-in pres-
5.3 idle {180 (6/0)} {180 (6/0)}
sure MPa
Accumulator charge pres- Hydraulic oil
sure
Charge: <kg/cm2> 20.6 (+1.47/0) 20.6 (+1.47/0)
temperature: 45
Cut-out
to 55 °C {210 (+15/0)} {210 (+15/0)}
pressure
Hydraulic oil temperature: 45

6-1 to 55 °C 31.36 31.36
Work equipment control Engine: At high idle Bucket (+0.98/-0.29) (+0.98/-1.27)
valve relief pressure Tilt Relief MPa {320 (+10/-3)} {320 (+10/-13)}
<kg/cm2>
Hydraulic oil temperature: 45
6-2 3.72 to 3.92 3.52 to 3.92
to 55 °C
6. Hydraulic system
PPC Oil Pressure {38 to 40} {36 to 40}

Engine: At high idle
6-3 Raise 13.5 ± 0.5 13.5 ± 0.5
Lift arm speed (standard
and high lift arms) Lower 5.3 ± 0.5 5.3 ± 0.5
a For work equipment
posture, see the stan- Float 5.0 ± 0.5 5.0 ± 0.5
dard value table. Engine: At
6-4 high idle Full stroke tilt
4.1 ± 0.3 4.1 ± 0.3
Bucket speed (standard back
and high lift arms)
a For work equipment Full stroke
3.2 ± 0.3 3.2 ± 0.3
posture, see the stan- dump
dard value table.
Brake 14.74
Front 15.7{1,601}
charge: {1,501}
7-1 MPa
Cut-out 2
Brake accumulator <kg/cm >/
pressure 14.74
pressure leakage Rear 15min 15.7{1,601}
Engine {1,501}
7 Accumulator
stopped
Lift arm: Maximum height
Lock the work equipment
lever and stop the engine.
7-2
With the engine stopped for
PPC
one to three minutes, unlock mm 3 1
accumulator pressure
the work equipment lock
leakage
lever and perform a lift arm
lower operation. The lift arm
should lower to the ground.
Bucket hinge
With lift arm and bucket mm/15mi Max. 250 Max. 250
8 Hydraulic drift pin
at a level position n
Bucket edge Max. 100 Max. 100
Set the lift arm and bucket in the measuring posture and stop the engine.
30-240 WA1200-6
Pm Clinic
Pm clinic service
Memo: Enter phenomena and information you noticed through today’s check
WA1200-6 30-241
Pm Clinic
Pm clinic service
30-242 WA1200-6
SEN0547512-00 40-1
WA1200-6
WHEEL LOADER
Shop Manual 4-01
WA1200-6

WA1200-6 60001 and up
40 Troubleshooting 40-1
WA1200-6 40-1
Contents
Contents 40-2
40 Troubleshooting
General information on troubleshooting.................................................................................. 40- 8
Sequence of events in troubleshooting................................................................................ 40- 9
Check before troubleshooting .............................................................................................. 40- 10
Classification and procedures of troubleshooting ................................................................ 40- 21
Breakage of hydraulic cylinder............................................................................................. 40- 24
Failure codes table............................................................................................................... 40- 27
Information in troubleshooting table..................................................................................... 40- 44
Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... 40- 46
Layout drawing of connector pins ........................................................................................ 40- 48
Connector list and layout ..................................................................................................... 40- 84
T- branch box and T- branch adapter table ......................................................................... 40- 104
Table of fuse locations ......................................................................................................... 40- 107
Troubleshooting by failure code.............................................................................................. 40- 110
Failure code [1500L0] Double Engagement of Transmission Clutches ............................... 40- 110
Failure code [1540N1] T/M overrun ..................................................................................... 40- 111
Failure code [15B0NX] T/M Oil Filter Clogged..................................................................... 40- 112
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit .................................................. 40- 114
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect ......................................... 40- 116
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit .................................................. 40- 118
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect ......................................... 40- 120
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit................................................... 40- 122
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect.......................................... 40- 124
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit................................................... 40- 126
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect.......................................... 40- 128
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit .................................................. 40- 130
Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect ......................................... 40- 132
Failure code [2F00MA] Parking brake circuit failure ............................................................ 40- 135
Failure code [2G42ZG] Accumulator Oil Press. F Low ........................................................ 40- 138
Failure code [2G43ZG] Accumulator Oil Press. R Low........................................................ 40- 140
Failure code [44K0L4] Bucket cylinder position detector SW failure ................................... 40- 142
Failure code [7REAKA] ACC Signal Malfunction ................................................................. 40- 143
Failure code [989P00] Direction protection warning ............................................................ 40- 144
Failure code [989Q00] Work equipment protection ............................................................. 40- 144
Failure code [989R00] Tire slip ............................................................................................ 40- 145
Failure code [989S00] Parking Brake Dragging................................................................... 40- 146
Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF).................................. 40- 148
Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) ................................... 40- 149
Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) ................................... 40- 150
Failure code [989W00] Stationary steering (Brake: ON, Load: ON) .................................... 40- 151
Failure code [AA1ANX] Air Cleaner 1 Clogging................................................................... 40- 152
Failure code [AA1BNX] Air Cleaner 2 Clogging................................................................... 40- 154
Failure code [AA1CNX] Air Cleaner 3 Clogging................................................................... 40- 156
Failure code [AA1DNX] Air Cleaner 4 Clogging................................................................... 40- 158
Failure code [AB00L6] Discharge of alternator R terminal................................................... 40- 160
Failure code [AB00MA] Discharge of alternator R terminal ................................................. 40- 162
Failure code [AB00MB] Discharge of alternator R terminal ................................................. 40- 164
Failure code [B@BCZK] Drop in Engine Coolant Level....................................................... 40- 166
Failure code [b@C5ZK] Low brake fluid level (before engine start) .................................... 40- 168
40-2 WA1200-6
Contents
Failure code [B@C5ZK] Low brake fluid level (while engine is running) ............................. 40- 169
Failure code [B@C6NS] High brake oil temp. ..................................................................... 40- 170
Failure code [b@CENS] High torque converter oil temp. .................................................... 40- 171
Failure code [B@CENS] Very high torque converter oil temp. ............................................ 40- 172
Failure code [B@GAZK] Low battery 1 fluid level................................................................ 40- 174
Failure code [B@GBZK] Low battery 2 fluid level................................................................ 40- 176
Failure code [B@GCZK] Low battery 3 fluid level ............................................................... 40- 178
Failure code [B@HANS] High hydraulic oil temp................................................................. 40- 180
Failure code [B@HAZK] Low hydraulic oil level .................................................................. 40- 181
Failure code [D191KA] Neutral Output Relay Disconnection .............................................. 40- 182
Failure code [D191KB] Neutral Output Relay hot short ....................................................... 40- 184
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit)............ 40- 186
Failure code [D19MKY] SW pump PNC solenoid Relay hot short....................................... 40- 188
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure ...................................... 40- 190
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure ...................................... 40- 192
Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit) ............ 40- 194
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short ....................................... 40- 196
Failure code [D5ZHKZ] Starting Switch C signal circuit failure ............................................ 40- 198
Failure code [D5ZHL6] Ignition C terminal Circuit Failure ................................................... 40- 200
Failure code [DAF5KP] Monitor Panel 5 V source sys Error ............................................... 40- 202
Failure code [DAFRKR] Communication Lost Monitor Panel Controller.............................. 40- 204
Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source ................... 40- 206
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal ................................... 40- 208
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source ............. 40- 210
Failure code [DAQRKR] Communication Lost T/M Controller ............................................. 40- 212
Failure code [DAQRMA] Defective Option Selection Data in Transmission ........................ 40- 214
Failure code [DB2RKR] Communication Lost Engine Controller......................................... 40- 216
Failure code [DB90KK] Drop in Work Controller Main Power Source ................................. 40- 218
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal .................................... 40- 220
Failure code [DB92KK] Solenoid Voltage Failure (Work controller) .................................... 40- 222
Failure code [DB95KX] 5 V source sys Error (Work controller) ........................................... 40- 224
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller ............ 40- 226
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller ........ 40- 228
Failure code [DB9RMC] Communication Lost (Work Controller)......................................... 40- 230
Failure code [DBB0KK] VHMS source voltage Error ........................................................... 40- 232
Failure code [DBB0KQ] VHMS Connector Mismatch .......................................................... 40- 234
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V) ........................ 40- 236
Failure code [DBB5KP] VHMS 5 V source sys Error ........................................................... 40- 238
Failure code [DBBQMC] Communication Lost (VHMS CAN0) ............................................ 40- 243
Failure code [DBBRKR] Communication Lost VHMS Controller ......................................... 40- 245
Failure code [DBBRMC] Communication Lost (VHMS CAN1) ............................................ 40- 246
Failure code [DD10KX] Verification Mode SW Failure ........................................................ 40- 248
Failure code [DD1ALD] Remote positioner upper side set sw failure .................................. 40- 250
Failure code [DD1BLD] Remote positioner lower side set sw failure .................................. 40- 252
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit .......................................... 40- 254
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit ....................... 40- 256
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit....................... 40- 258
Failure code [DDB6L4] Neutral Signal Malfunction ............................................................. 40- 260
Failure code [DDD7KA] Speed control dial circuit (Low Voltage) ........................................ 40- 262
Failure code [DDD7KB] Speed control dial circuit (High Voltage) ....................................... 40- 264
Failure code [DDDBKA] Traction control dial circuit (Low Voltage) ..................................... 40- 266
Failure code [DDDBKB] Traction control dial circuit (High Voltage) .................................... 40- 268
WA1200-6 40-3
Contents
Failure code [DDE5MA] Emergency steering signal Failure................................................ 40- 270

Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection........................................ 40- 272
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit........................................... 40- 274
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)......... 40- 276
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect .. 40- 278
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit ...................................... 40- 280
Failure code [DDW9LD] Kickdown Switch Short Circuit ...................................................... 40- 282
Failure code [DGE5KX] Ambient air temp Sensor Failure ................................................... 40- 284
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect ............. 40- 286
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit 40- 288
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)........... 40- 290
Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure........................................ 40- 292
Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection................................. 40- 294
Failure code [DGR2KX] Brake oil temp. sensor circuit failure ............................................. 40- 296
Failure code [DGT1KX] T/C oil temp. sensor circuit failure ................................................. 40- 298
Failure code [DH20KX] Torque converter pressure sensor circuit....................................... 40- 300
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit).............. 40- 302
Failure code [DH21KB] Loader pump oil press sensor hot short......................................... 40- 304
Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit) ............................ 40- 306
Failure code [DHPCKX] Boom bottom press. sensor circuit failure ..................................... 40- 308
Failure code [DHPCKY] Boom bottom press. hot short ....................................................... 40- 310
Failure code [DHPDKX] Boom head press. sensor circuit failure ........................................ 40- 312
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect ............................ 40- 314
Failure code [DHT2L6] T/M oil filter sensor circuit failure .................................................... 40- 316
Failure code [DHT3KX] Transmission main pressure sensor circuit.................................... 40- 318
Failure code [DHT4KX] Main PPC oil pressure sensor circuit ............................................. 40- 320
Failure code [DHT5KX] Torque converter intake pressure sensor circuit............................ 40- 322
Failure code [DHT8KX] Steering Oil Press. Sensor Failure................................................. 40- 324
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit........................... 40- 326
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect................... 40- 328
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit .................. 40- 330
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect............................................ 40- 332
Failure code [DHU2KB] F Brake Oil press Sensor Hot short............................................... 40- 334
Failure code [DHU2KX] F Brake Oil press Sensor Failure .................................................. 40- 336
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect ........................................... 40- 338
Failure code [DHU3KB] R Brake Oil press Sensor Hot short .............................................. 40- 340
Failure code [DHU3KX] R Brake Oil press Sensor Failure .................................................. 40- 341
Failure code [DJF1KA] Fuel level sensor circuit Disconnection........................................... 40- 343
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit).................. 40- 344
Failure code [DK30KY] Steering lever angle sensor circuit hot short .................................. 40- 345
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit) ......... 40- 346
Failure code [DK59KY] Boom lever potentiometer (main) hot short .................................... 40- 348
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure............................... 40- 349
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)........... 40- 352
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short...................................... 40- 354
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit) ....... 40- 356
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short .................................. 40- 358
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure............................. 40- 359
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)......... 40- 362
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short.................................... 40- 363
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) .............................. 40- 364
Failure code [DKA0KX] Boom angle sensor circuit failure................................................... 40- 366
Failure code [DKA0KY] Boom angle sensor circuit hot short............................................... 40- 368
Failure code [DKA0L0] Boom angle sensor failure .............................................................. 40- 370
40-4 WA1200-6
Contents
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)............................. 40- 372
Failure code [DKD0KY] Frame angle sensor circuit hot short ............................................. 40- 373
Failure code [DKD0KZ] Frame and steering angle sensor failure ....................................... 40- 374
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect ............................................ 40- 375
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short ............................................... 40- 376
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect ............................................ 40- 378
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short................................................ 40- 380
Failure code [DLE2KA] Engine Speed Sensor Disconnection............................................. 40- 382
Failure code [DLE2LC] Engine Speed Sensor Short Circuit................................................ 40- 384
Failure code [DLF6LC] Tire speed sensor circuit ................................................................ 40- 386
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect....................................... 40- 388
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit ..................................... 40- 390
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit ................................. 40- 392
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection .............................. 40- 394
Failure code [DT20KB] Transmission cut off indicator Output short circuit ......................... 40- 396
Failure code [DT21KB] Speed Control indicator Output short circuit................................... 40- 397
Failure code [DUM8KB] VHMS Operation lamp Short Circuit ............................................. 40- 398
Failure code [DV00KY] Buzzer circuit hotshort (for usually)................................................ 40- 400
Failure code [DV01KY] Buzzer circuit hotshort (for special)................................................ 40- 402
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection......................... 40- 404
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit ........................... 40- 405
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short ...................... 40- 406
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection ........................ 40- 407
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit ........................... 40- 408
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short...................... 40- 409
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection ...................... 40- 410
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit ......................... 40- 411
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short.................... 40- 412
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection .............................. 40- 416
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit ............................ 40- 417
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short ................................ 40- 418
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection................................... 40- 419
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault...................................... 40- 420
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short........................................... 40- 421
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit ................................. 40- 423
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...................................... 40- 424
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection ........................ 40- 428
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault ................................. 40- 429
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short ...................................... 40- 430
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection ...................................... 40- 431
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault ........................................... 40- 432
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short .............................................. 40- 433
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit..................................... 40- 435
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short ......................................... 40- 436
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection ............................ 40- 437
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit............................... 40- 438
WA1200-6 40-5
Contents
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short.......................... 40- 439
Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection .................. 40- 440
Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit ...................... 40- 441
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short .......................... 40- 442
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection.................... 40- 443
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit ....................... 40- 444
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short............................ 40- 445
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection..................... 40- 446
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit ........................ 40- 447
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short............................. 40- 448
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection ...................... 40- 449
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit............................ 40- 450
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short ................................ 40- 451
Failure code [DWNAKA] NC solenoid disconnection........................................................... 40- 452
Failure code [DWNAKB] NC solenoid short circuit .............................................................. 40- 453
Failure code [DWNAKY] NC solenoid hot short................................................................... 40- 454
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit) ............... 40- 455
Failure code [DXA1KY] Loader pump solenoid Relay hot short .......................................... 40- 457
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)............... 40- 459
Failure code [DXF0KA] AJSS EPC solenoid disconnection ................................................ 40- 461
Failure code [DXF0KB] AJSS EPC solenoid short circuit .................................................... 40- 463
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection ................................... 40- 465
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit...................................... 40- 467
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short................................. 40- 469
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection.................................. 40- 471
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit..................................... 40- 473
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short ............................... 40- 475
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection................................... 40- 477
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit ..................................... 40- 479
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short ................................ 40- 481
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection ..................................... 40- 483
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit ........................................ 40- 485
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short................................... 40- 487
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection...................................... 40- 489
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit ........................................ 40- 491
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short ................................... 40- 493
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection ........................... 40- 494
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit .............................. 40- 495
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V.................. 40- 496
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction ............................... 40- 497
Troubleshooting of electrical system (E-mode),...................................................................... 40- 499
E-1 Remote positioner "RAISE" or "LOWER" LED does not light up................................... 40- 499
E-2 Open circuit or ground fault in check lamp system........................................................ 40- 500
E-3 Machine monitor does not operate................................................................................ 40- 501
E-4 Turn signal lamp does not light up ................................................................................ 40- 502
E-5 Defective parking lamp.................................................................................................. 40- 504
E-6 Defective front working lamp ......................................................................................... 40- 506
E-7 Defective rear working lamp.......................................................................................... 40- 508
E-8 Headlamp does not light up........................................................................................... 40- 510
E-9 Service meter does not work, or service meter works while engine is stopped. ........... 40- 512
E-10 Monitor panel controller does not sound buzzer ......................................................... 40- 514
E-11 Defective auto-greasing system .................................................................................. 40- 516
Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 518
40-6 WA1200-6
Contents
Before performing troubleshooting of work equipment hydraulic system (how to use the
multi monitor) ....................................................................................................................... 40- 518
Work equipment hydraulic system, general ......................................................................... 40- 528
Work equipment oil pressure group..................................................................................... 40- 530
Before performing troubleshooting of steering oil pressure system (how to use the multi
monitor)................................................................................................................................ 40- 595
Checking steering related standard values.......................................................................... 40- 608
Steering oil pressure system, general ................................................................................. 40- 609
Steering oil pressure group.................................................................................................. 40- 610
Brake oil pressure system, general ..................................................................................... 40- 650
Brake oil pressure group...................................................................................................... 40- 651
Information contained in troubleshooting table (H mode) .................................................... 40- 701
H-1 Torque converter oil temperature rises too high (overheats) ........................................ 40- 702
H-2 Turning or response of steering is poor ........................................................................ 40- 705
H-3 AJSS lever is hard to operate ....................................................................................... 40- 708
H-4 Steering shakes or jolts................................................................................................. 40- 710
H-5 Wheel brake does not work at all or is weak................................................................. 40- 712
H-6 Lift arm speed is low or lift arm rising force is insufficient ............................................. 40- 714
H-7 Shock is large when lift arm stops ................................................................................ 40- 717
H-8 Hydraulic oil temperature rises too high (overheating) ................................................. 40- 718
WA1200-6 40-7
General information on troubleshooting
Symptom and troubleshooting numbers
General information on troubleshooting 40-8

Symptom and troubleshooting numbers 40-8
(Rev. 2010/03)
k Stop the machine on a level place, and check that the lock pin, blocks, and parking brake are se-
curely fitted.
k When performing the operation with two or more service technitians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the cable from the negative (–) terminal of the bat-
tery first.
k When removing the plug or cap from a component which is under pressure of oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to perform repairs swiftly, and to pre-
vent reoccurrence of the failure. When performing troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When performing troubleshooting, do not hurry 2) Perform checks on items listed in "Checks
to disassemble the components. before starting".
If components are disassembled immediately 3) Perform checks on other checking items.
after any failure occurs: 4) Check other maintenance matters which can
q Parts that have no connection with the failure be checked externally and are considered to
or other unnecessary parts will be disassem- be necessary.
bled.
q It will become impossible to find the cause of 4. Checking failure symptom
the failure. Check the extent of the failure by yourself, and
It will also cause a waste of manhours, parts, or judge whether it is a real failure or a problem with
oil or grease, and at the same time, will also lose the method of operation, etc.
the confidence of the user or operator. a When operating the machine to reproduce
For this reason, when performing trouble- the failure symptom, do not perform any in-
shooting, it is necessary to perform thorough spection or measurement that may make the
prior investigation and to perform trouble- problem worse.
shooting in accordance with the fixed procedure.
5. Troubleshooting
2. Points to ask the user or operator Use the results of the investigation and inspec-
1) Have any other problems occurred apart tion in Items 2 to 4 to narrow down the probable
from the problem that has been reported? causes of the failure, then use the trouble-
2) Was there anything strange about the shooting flowchart to locate the failure exactly.
machine before the failure occurred? a The basic procedure for troubleshooting is as
3) Did the failure occur suddenly, or were there follows.
problems with the machine condition before 1] Start from the simple points.
the failure? 2] Start from the most likely points.
4) Under what conditions did the failure occur? 3] Investigate other related parts or informa-
5) Had any repairs been performed before the tion.
failure? When were these repairs
performed? 6. Measures to remove root cause of failure
6) Has the same kind of failure occurred Even if the immediate failure is removed, the
before? same failure may occur again, unless the root
cause of the failure is repaired. To prevent this,
3. Check before troubleshooting always investigate why the cause of the failure
1) Check the machine for other symptoms of occurred. Then, remove the root cause.
failure.
40-8 WA1200-6
Sequence of events in troubleshooting
Sequence of events in troubleshooting 40-9

(Rev.2007.12)
WA1200-6 40-9
Check before troubleshooting
Check before troubleshooting 40-10

No. Item Criterion Remedy
1 Check of unusual noise and smell – Repair
2 Check of engine for dirt – Remove
3 Check of engine for water leakage – Repair
4 Check of engine for oil leakage – Repair

a: Engine, lubricating oil and coolant
5 Check of fuel line for leakage – Repair
6 Check of radiator for clogging – Remove
7 Check of fuel level and type – Refill with fuel
8 Check of foreign material in fuel – Clean and drain
9 Check of fuel filter – Replace
Between H
10 Check of engine oil level (in oil pan) and type Refill with oil
and L
Between H
11 Check of coolant level (in sub tank) Refill with coolant
and L
No clog-
ging indica-
12 Check of air cleaner for clogging Clean or replace
tion on
monitor
1 Check for unusual noise and smell – Repair
2 Check for oil leakage – Repair
Between H
3 Check of hydraulic oil Refill with oil
b: Hydraulic and mechanical equipment
and L
4 Check of hydraulic oil strainer – Clean and drain
5 Check of hydraulic oil filter – Replace
Between H
6 Check of power train case oil level Refill with oil
and L
7 Check of power train pump strainer – Clean and drain
8 Check of transmission oil filter and torque converter oil filter – Clean and drain
Between H
9 Check of damper case oil level Refill with oil
and L
Between H
10 Check of final drive case oil level Refill with oil
and L
11 Bleed air – Bleed air
40-10 WA1200-6
No. Item Criterion Remedy
1 Check of battery terminals for looseness and corrosion – Retighten or replace
2 Check of alternator terminals for looseness and corrosion – Retighten or replace
3 Check of starting motor terminals for looseness and corrosion – Retighten or replace
during illu-
minance
4 Check of battery voltage (with engine stopped) Charge or replace
increase
adjustment
Between H
5 Check of battery electrolyte level Add or replace
and L
6 Check of wiring harness for discoloration, burnt areas and cover peeling – Repair or replace
7 Check of wiring harness for coming off from clamp and sagging – Repair
c: Electrical equipment
8 Check of grounding – Repair
9 Check for loose connector and damaged lock – Repair or replace
10 Check of connector pin for corrosion, bending and deformation – Repair or replace
11 Check for water and foreign material in connector – Dry, clean or replace
12 Check of wiring harness for open or short circuit – Repair or replace
13 Check of fuse for blowout and corrosion – Replace
14 Check of circuit breaker – Push in reset button

After sev-
eral min-
utes
15 Check of alternator voltage (when engine speed is medium or higher) Replace
operation:
27.5 - 29.5
V
Check of battery relay operation sound (when the starting switch is turned
16 – Replace
to ON or OFF position)
e: Interior parts d: Exterior parts
1 Check of undercarriage – Repair
2 Check of handrails and steps – Repair
3 Check of mirrors – Clean or repair
1 Check of gauges and monitors – Clean or replace
2 Check of seat belt – Repair
WA1200-6 40-11
Testing procedure before troubleshooting 40-12

Walk-around check 40-12
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles and leaking oil and fuel around hot engine parts such as the engine
muffler or turbocharger and around battery may cause a machine fire. Check carefully, and if any
problem is found, repair it.
a a1 and a2, ---, b1, b2, --- correspond to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell b3. Check of hydraulic equipment, hydraulic
Check for unusual noise and smell. tank, hoses and joints for oil leakage
Some causes of unusual noise and smell can Check and repair any oil leaks.
damage the machine if they are left as they are.
Therefore, stop the machine immediately when c1. Check around battery and dirt removal
you find any abnormality. Check for and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
a2. Check around engine and dirt removal the battery.
Check for and remove any accumulated dirt
around the engine and any combustibles (dead d1. Check of undercarriage for defect, wear,
leaves, twigs, etc.) on hot engine parts such as loose bolts and oil leakage from axle and final
the engine muffler, turbocharger, etc. drive
Repair any failures.
a3. Check of engine for water leakage
a4. Check of engine for oil leakage d2. Check of handrails and steps for defect and
Check for any oil leaks from the engine and any loose bolts
water leaks from the cooling system, and then Repair any failures and retighten any loose
repair any failures. bolts.
a5. Check for leakage from fuel line d3. Check and cleaning of rear view mirrors
Check for any fuel leaks and damaged hoses Check for and repair any defective and broken
and tubes, and then repair any failures. rear view mirrors.
Clean the mirror surfaces and adjust their angles
a6. Check of radiator and dirt removal so that the operator can see the area behind
Check for and remove any accumulated dirt and machine at the operator's seat.
combustibles (dead leaves, twigs, etc.) around
the radiator. e1. Check of gauges and monitors for defect
For removal of dirt from the radiator, see the Check the gauges and monitors inside the oper-
Operation and Maintenance Manual, "Cleaning ator's cab. If any of them is defective, replace it.
and testing of radiator fins, oil cooler fins, after- Clean up the surfaces.
cooler fins, fuel cooler fins and air conditioner
condenser fins (machine with the air condi- e2. Check of seat belt and mounting hardware
tioner)". Check the hooks, locks and hook fittings for
damage, and then repair any failures.
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage
and hoses for cracks and excessive wear, check
that the clearances in them are within the normal
range, and then repair any failures.
40-12 WA1200-6
Test according to testing procedure 40-13 a8. Check for foreign material in fuel
a. Engine, lubricating oil and coolant 40-13 1. Open three drain cocks (1) on the right side of
the fuel tank.
a7. Check of fuel level and type 2. Place a container under the drain hose to
k Fuel is flammable and dangerous.Do not receive the drained fuel.
bring any open flame near fuel. 3. Turn the drain valve to the "OPEN" position to
k When adding fuel, take care not to let it over- discharge the sediment and water in the bottom
flow. together with the fuel.
k Wipe off completely any spilt fuel.If fuel has 4. When only the clean fuel flows out, close the
spilled over soil or sand, remove that soil or drain valve.
sand.
1. Turn the starting switch to the ON position and
check the fuel level with fuel level gauge (1) on
the monitor panel.
After checking, return the switch to the OFF posi-
tion.
2. If the fuel level is low, open oil filler cap (1) of the
fuel tank and add fuel through the filler port to the
necessary level.
q If the filter of the breather is clogged, the
pressure in the tank decreases and fuel may
not be supplied. To prevent this, clean the fil-
ter.
WA1200-6 40-13
k Immediately after the engine is stopped, its a9. Check of fuel filter
parts and oil are still very hot and may cause k Immediately after the engine is stopped, its
burn injury. Accordingly, wait until they have parts and oil are still very hot and may cause
cooled down before starting the work. burn injury. Accordingly, wait until they have
k High pressure is generated inside the engine cooled down before starting the work.
fuel piping system when the engine is run- k High pressure is generated inside the engine
ning.Wait for at least 30 seconds after stop- fuel piping system when the engine is run-
ping the engine until the internal pressure ning.Wait for at least 30 seconds after stop-
decreases, and then replace the filter. ping the engine until the internal pressure
decreases, and then replace the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a spe- k Do not bring any open flame near the filter.
cial filter that has highly efficient filtering perfor- a Komatsu genuine fuel filter cartridges use a spe-
mance.When replacing, always use a Komatsu cial filter that has highly efficient filtering perfor-
genuine cartridge. mance.When replacing, always use a Komatsu
genuine cartridge.
a When testing and servicing the fuel system, be
extremely careful that no foreign material enters. a When testing and servicing the fuel system, be
If any dirt sticks, remove it completely by using extremely careful that no foreign material enters.
fuel. If any dirt sticks, remove it completely by using
q Prepare a container to receive the fuel. fuel.
q Prepare the filter wrench. q Prepare a container to receive the fuel.
q Prepare the filter wrench.
1. Turn supply valve (1) of the fuel tank to the

closed position.
2. Open the engine hood.

3. Loosen the plug at the bottom of filter cartridge
(2) and drain fuel from the cartridge.
40-14 WA1200-6
4. Place the fuel container under filter cartridge (2). a10. Check of engine oil level (in oil pan) and
5. By using the filter wrench, rotate filter cartridge type
(2) to the left to remove. k Immediately after the engine is stopped, its
parts and oil are still very hot and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.
a If the engine has been operated, wait for at least
15 minutes after stopping it, and check the oil
level.
a If the machine is inclining, make it level before
checking.
1. Stop the engine.
2. Open the engine hood.
3. Remove dipstick (1) and wipe off oil from the
dipstick with a cloth.
4. Insert dipstick (1) fully and pull it out.
6. Clean the filter bracket and apply thin film of oil

to the packing surface of the filter cartridge.
a Do not pour fuel into the filter cartridge.
5. When the oil level is between lines H and L on

dipstick (1), it is at the correct level.
If the oil level is below line L, add oil through oil
7. Install the filter cartridge. filler port (2).
6. If the oil level is above H
a When installing the filter cartridge, tighten it 1) Remove the cover from the machine bottom
by 3/4 turns after its O-ring has been securely and place a drain oil container directly below
placed on the sealing surface of the filter it.
head. 2) Loosen drain plug (1) to drain excess oil.
a If the filter cartridge is over tightened, fuel will
leak because of the damage to the O-ring. If
the filter cartridge is not tightened sufficiently,
fuel will also leak through the clearance at the
packing. Therefore, observe the tightening
angle.
8. Turn valve (1) at the fuel tank bottom to "OPEN"
(O) position.
9. Bleed air. For details, see Testing and adjusting,
"Bleeding air from fuel circuit".
3) Check the oil level again.

7. When the oil is at the correct level, tighten the oil
filler cap securely and close the engine hood.
WA1200-6 40-15
a11. Check of coolant level

k For usual check, it is not necessary to open
the radiator cap.Check the coolant level with
the gauge level while the engine is cold.
k Immediately after the engine is stopped, the
coolant is hot and pressure is accumulated
in the radiator.If the cap is opened under
these conditions, you may be scalded.When
the radiator cap needs to be removed,wait
until the temperature drops and rotate the
cap slowly to release the pressure and re-
move it with care.I
1. Open the cover on the rear left side of the
machine, and check that the coolant level is 3. After adding the coolant, tighten the cap
between the FULL and LOW marks on the securely.
gauge.
a12. Check of air cleaner for clogging
k When using compressed air for cleaning, put
on personal protective items such as protec-
tive eyeglasses, gloves, dust mask, etc. to
protect yourself from dirt that will fly out.
k Removing the outer element from the air
cleaner body forcibly is dangerous .When
working in high places or on unstable foot-
ing, you may fall off due to the reaction when
you pull out the outer element. Take care.
Checking
Clean the air cleaner element if air cleaner clogging
2. If the reservoir tank is empty, there may be warning (A) is displayed on the multi monitor.
coolant leakage.After checking, repair any
defects immediately.If no defect is found, check
the coolant level in the radiator. If the level is low,
add coolant to the radiator through coolant filler
port (1).Check that the coolant level is above the
bottom surface of the strainer.
a If the element is cleaned frequently before the air

cleaner clogging warning is displayed, the true
performance of the air cleaner will not be real-
ized and the cleaning effect will decrease.
a If the outer element is checked or cleaned while
the engine is running, the dirt sticking to it will fall
into the inner element side more frequently and
enter and damage the engine. Be sure to stop
the engine before cleaning.
40-16 WA1200-6
Cleaning of element a After cleaning, light up the inside of the ele-

a Do not leave or store the element in direct sun- ment to check it. If the element has a small
light before or after cleaning it. hole or a thin part, replace it.
a Replace the outer element if it is cleaned six
times repeatedly or used throughout a year.Re-
place the inner element as well at the same time.
a If the air cleaner clogging warning is displayed
soon after cleaning, replace both the inner and
outer elements even if the outer element has not
been cleaned up to six times.
1. Remove the air cleaner cover and remove
elements (1) and (2).
4. Check and remove any dirt, oil, etc. sticking to

the sealing surface of the cleaned or new
element.
a If the element or O-ring used for more than 1
year is cleaned and reused, it can cause a
trouble. Therefore, do not reuse it.
a Do not use the element if its pleats, gasket or
seal is damaged.
Replacement of element
1. Remove elements (1) and (2). For details, see
"Cleaning of outer element".
2. Install new elements (1) and (2) to air cleaner
body (3) promptly.
2. Blow dry compressed air (Max. 0.69 MPa

{7 kg/cm2}) along the inside pleats of the outer
element.
3. Next, blow air along the outside pleats, and blow
again along the inside pleats.
WA1200-6 40-17
b. Hydraulic and mechanical equipment 40-18 4. If the oil level is below sight gauge (1), open the
inspection cover above the steps and add oil
b3. Check of hydraulic oil level through oil filler port (6).The oil level can be
k Immediately after the engine is stopped, its checked with dipstick (1) when adding oil.
k If the oil filler cap is removed quickly, the oil
may spurt out. Accordingly, rotate the oil fill-
er cap slowly to release the internal pressure
and remove it with care.
1. Lower the work equipment to the ground and
stop the engine. Check the oil level and add new
oil if necessary.
2. Turn the starting switch to the ON position within
15 seconds after stopping the engine and
operate the work equipment control lever to the
stroke end in each direction to release the
internal pressure.
3. Oil level is correct if it is seen in sight gauge (1).
a If the oil level is low, add oil through oil filter
port (6).
a Do not add oil to above line H of dipstick (1).
Too much oil may damage the hydraulic cir-
cuit and spurt out.
a If the oil level is above line H, stop the engine
and wait until the hydraulic oil cools down.
Then, loosen the drain valve at the hydraulic
tank bottom to drain excessive oil through the
drain plug into a container.
40-18 WA1200-6
b4. Check of hydraulic oil strainer 4. Loosen nut (5) and remove strainer (4).
k Immediately after the engine is stopped, its 5. Remove all dirt from strainer (4), then wash in
parts and oil are still very hot and may cause clean diesel oil or flushing oil.
burn injury. Accordingly, wait until they have If strainer (4) is damaged, replace it with a new
cooled down before starting the work. one.
k If the oil filler cap is removed quickly, the oil 6. Install strainer (4) to holder (3) and tighten nut
may spurt out. Accordingly rotate the oil filler (5).
cap slowly to release the internal pressure 3 Nut:
and remove it with care. 59–74 Nm {6.0–7.5 kgm}
1. Stop the engine and remove the oil filler cap of 7. Install holder (3).
the hydraulic tank to release the internal pres- Replace O-ring (6) of the holder with a new one.
sure.
2. Remove the mounting bolts to remove cover (1).
3. Loosen bolt (2) and remove holder (3) together

with strainer (4) from the hydraulic tank.
WA1200-6 40-19
b5. Check of hydraulic oil filter

k Immediately after the engine is stopped, its
k If the oil filler cap is removed quickly, the oil
may spurt out. Accordingly rotate the oil filler
cap slowly to release the internal pressure
and remove it with care.
1. On a level and firm surface, lower the work
equipment to the ground and stop the engine.
2. Remove hydraulic tank oil filler cap (5) and filter
case plug (1) to release the internal pressure.
7. Remove spring (6) and bypass valve (7), and

then remove element (8).
8. Check inside the tank for foreign material, and
clean as necessary.
9. Install the new element, and then set bypass
valve (7), spring (6), and cover (4) to the tank.
At this time, replace O-ring (9) of the cover with
a new one.
10. While holding down the cover, tighten the
mounting bolts evenly.
11. Fill with the specified amount of oil through oil
filler port (F), then install the cap and filter case
plug (1).
3. Prepare a container to receive the drained oil. a If air bleeding is insufficient, the piston
4. Remove drain plug (3) at the tank bottom and pumps and cylinders may be damaged.
loosen drain valve (2) to drain the oil. Bleed air completely.
a When loosening drain plug (3), take care that 12. After bleeding air, tighten plug (1).
the oil does not splash over you. 3 Plug:
9.8–12.8 Nm {1.0–1.3 kgm}
13. Lay the bucket flat on the ground and stop the
engine.
14. Check the hydraulic oil level to confirm it is at the
specified level.
15. Check the filter cover mounting section for oil
leakage.
5. After draining the oil, tighten drain plug (3) and

drain valve (2).
6. Remove bolts (5), and then remove filter cover
(4) and pull out the element.
When removing the bolts, keep pressing down
the cover since it may fly out by the force of
spring (6).
a Check the bottom of filter case, and if there is
any dust etc., remove it.Take good care that
the dirt does not fall into the hydraulic tank.
40-20 WA1200-6
Classification and procedures of troubleshooting
Classification and procedures of troubleshooting 40-21
Classification of troubleshooting 40-21

Mode Content
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
Procedure for troubleshooting 40-21

If a phenomenon which appears a source of a trouble occurs on the machine, select a proper troubleshooting
No. according to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting when action code and failure code are displayed on multi monitor:
If a action code and a failure code are displayed on the standard screen of multi monitor, perform the trou-
bleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple abnormalities occur simultaneously, all the codes are displayed repeatedly in order.Note
down all the failure codes.
2. Procedure for troubleshooting when a action code and a failure code are not displayed on multi
monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the multi monitor.(See next paragraph)
1) If a failure code is recorded, perform troubleshooting for the corresponding "Display of code" according
to the recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected.(See next paragraph)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a trouble that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show a trouble again and select the same
phenomenon from the table, "Phenomena as regarded failure and troubleshooting No.", and then
perform troubleshooting corresponding to that phenomenon in the "E-mode" or "H-mode".
3. Action to take after trouble is repaired

Clear all the failure codes in the electrical system abnormality record, referring to the next paragraph.
WA1200-6 40-21
Check of failure code 40-2

1. Procedure for switching to service mode and 2. Abnormality record display function
screen display The multi monitor logs the failures which
To use the service mode, perform the following occurred in the past or which are occurring at
procedure to change screen displays. present.
a With the standard screen displayed, press a After entering service ID, press the [F6]
the [F3] switch to go to the date setting dis- switch to display the service menu selecting
play screen. screen.
1) Date setting display screen
The service mode is accessed by way of the
this screen.
q Select the abnormality record by pressing

[F3] or [F4] switch.
q Press the [F6] switch to move to the abnor-
q Press and release the [F2] and [F5] mality record screen.
switches at the same time to access the q Press the [F1] switch to return to the date set-
service ID input screen. ting screen.
screen returns to the standard screen. 1) Abnormality record display screen
2) Service ID input screen
q Scroll the item by pressing [F3] or [F4]

switch.
q Press the [F3] or [F4] switch to move to q Skip over three items to display every
the "numeric value" to be entered. fourth one by pressing [F2] or [F5].
q When the [F5] switch is pressed, the se- q Press the [F1] switch to return to the ser-
lected numeric value is entered. vice menu selecting screen.
a Repeat these steps to enter the numerals
for the service ID.
q Press the [F6] switch to enter the service
ID and the service menu selecting screen
appears.
q Press the [F1] switch to return to the date
setting screen.
40-22 WA1200-6
2) Information displayed on "Abnormality 1) Abnormality record memory clear

Record" screen
The abnormality record display screen
shows failure information on the screen as
follows.
(a): Failures occurring in reverse chronolog-
ical order
(b): Failure code
(c): Detail of failure
(d): Number of times the failure occurred
(e): Time and date of first occurrence
(f): Time and date of latest recovery
a For all the failure codes that the multi
monitor can record, see Troubleshooting,
"Fault code list".
q Select memory clear item abnormality re-
3. Memory clear function
cord by pressing [F3] or [F4] switch.
The memory clear function erases data stored in
q Press the [F6] switch to move to the ab-
the KOMTRAX Plus, including the abnormality
normality record erase confirm screen.
record, maintenance, trend, load map, and snap
shot.
2) Abnormality record memory clear confirma-
a After entering ID, press the [F6] switch to dis-
tion screen
play the service menu selecting screen.
whether to erase the abnormality record or
not. Confirm erasure by pressing the [F2] or
[F5] switch.
q Select memory clear by pressing [F3] or [F4]

switch.
q Press the [F6] switch to move to the memory
clear ID entry screen.
q Press the [F5] switch to clear the abnor-
q Press the [F1] switch to return to the date set-
mality record, and the screen returns to
ting screen.
a After entering memory clear ID, press the
[F6] switch to move to the memory clear
screen.
WA1200-6 40-23
Breakage of hydraulic cylinder
Breakage of hydraulic cylinder 40-24
Causes for hydraulic cylinder breakage include improper repair work performed on the machine.
As examples of problems resulting from improper repair work, "electric erosion" and "diesel-like ignition" are
mentioned below.
1. Electric erosion
Electric erosion mentioned here refers to damages resulting from welding. If a high-current flows through
the surrounding components, spark may occur and internal parts are welded together and damaged.
1) Cause
Since the ground clamp was attached far
away from the welding area, a high-current
has flown through a long distance between
the welding rod and ground clamp.Therefore,
spark occurred at inside the hydraulic
cylinder and pins that exist in the path, and
contacting parts were welded together.
2) Symptoms shown on the hydraulic cylinder

1] Sliding parts
q Linear scratches are spread by the sliding action (part a).
q Burnt spots are found at places where spark has occurred (Figure b).
q Figure c is a 100x magnification of Figure b.
2] Bearing area
q Pittings are found at places where
spark has occurred (part d).
These pittings, however, may not be
clearly seen in some cases.
<Reference>
q The cylinder rods, treated by induction
hardening, will usually not suffer pittings
and linear scratches suddenly.
q Pittings and damage spots may not be
apparent, however, linear scratches must
be examined under magnification.
40-24 WA1200-6
3) Countermeasures
q Be sure to attach the ground clamp as
close to the welding rod as possible.
q There should be no other components in
the path between the ground clamp and
welding rod.
2. Diesel-like ignition
Diesel-like ignition mentioned here refers to the phenomenon of ignition caused by air in the hydraulic
cylinder. The temperature and pressure of this air will be increased when the hydraulic circuit is
loaded.Under this condition, an ignition may occur in the same way as a diesel engine.
This phenomenon can also occur in hydraulic pumps.
1) Cause
Since the machine was used with insufficient air bleeding after repair work, a diesel-like ignition
occurred in the hydraulic cylinder and the seal was damaged by heat.
q Diesel-like ignition may occur either at the bottom side (part e) or head side (part f) of the hydraulic
cylinder.
2) Symptoms shown on the hydraulic

cylinder
1. Piston seal 3. Back ring
2. Backup ring 4. Wear ring
<Reference>
q Burns and breakage resulting from die-
sel-like ignition will occur locally (in a lim-
ited area).
q Closely examine parts for burns and dam-
age.
WA1200-6 40-25
q Burns are found.It may be difficult to find burns on originally black-colored parts (part g).
q Damage will occur locally (part h).
q A burned part (part i)
View A View C
View B View C, enlarged
3) Countermeasures
When the following work has been performed, bleed air from the hydraulic circuit. For details, see
Testing and adjusting, "Bleeding air from each part".
q Removal (and installation), repair of hydraulic components and the piping
q Replacement of filter elements and oil.
40-26 WA1200-6
Failure codes table
Failure codes table 40-27

Reference
Failure Component in Action
Failure (Displayed on screen) Category of record document
code charge code
page
1500L0 Double Engagement of Transmission Clutches Transmission E03 Mechanical system 40-110
1540N1 T/M overrun Transmission E02 Mechanical system 40-111
15B0NX T/M Oil Filter Clogged Monitor Panel E01 Mechanical system 40-112
15SAL1 ECMV (F) Fill Switch Short Circuit Transmission E03 Electrical system 40-114
15SALH ECMV (F) Fill Switch circuit Disconnect Transmission E01 Electrical system 40-116
15SBL1 ECMV (R) Fill Switch Short Circuit Transmission E03 Electrical system 40-118
15SBLH ECMV (R) Fill Switch circuit Disconnect Transmission E01 Electrical system 40-120
15SEL1 ECMV (1) Fill Switch Short Circuit Transmission E03 Electrical system 40-122
15SELH ECMV (1) Fill Switch circuit Disconnect Transmission E01 Electrical system 40-124
15SFL1 ECMV (2) Fill Switch Short Circuit Transmission E03 Electrical system 40-126
15SFLH ECMV (2) Fill Switch circuit Disconnect Transmission E01 Electrical system 40-128
15SGL1 ECMV (3) Fill Switch Short Circuit Transmission E03 Electrical system 40-130
15SGLH ECMV (3) Fill Switch circuit Disconnect Transmission E01 Electrical system 40-132
2F00MA Parking brake circuit failure Monitor Panel E03 Electrical system 40-135
2G42ZG Accumulator Oil Press. F Low Monitor Panel E03 Mechanical system 40-138
2G43ZG Accumulator Oil Press. R Low Monitor Panel E03 Mechanical system 40-140
Boom Bucket &
44K0L4 Bucket cylinder position detector SW failure E01 Electrical system 40-142
AJSS
7REAKA ACC Signal Malfunction KOMTRAX Plus E01 Electrical system 40-143
989P00 Direction protection warning KOMTRAX Plus – Electrical system 40-144
989Q00 Work equipment protection KOMTRAX Plus – Electrical system 40-144
989R00 Tire slip KOMTRAX Plus – Electrical system 40-145
989S00 Parking Brake Dragging KOMTRAX Plus – Mechanical system 40-146
989T00 Stationary steering (Brake: OFF, Load: OFF) KOMTRAX Plus – Mechanical system 40-148
989U00 Stationary steering (Brake: OFF, Load: ON) KOMTRAX Plus – Mechanical system 40-149
989V00 Stationary steering (Brake: ON, Load: OFF) KOMTRAX Plus – Mechanical system 40-150
989W00 Stationary steering (Brake: ON, Load: ON) KOMTRAX Plus – Mechanical system 40-151
AA1ANX Air Cleaner 1 Clogging Monitor Panel E01 Mechanical system 40-152
AA1BNX Air Cleaner 2 Clogging Monitor Panel E01 Mechanical system 40-154
AA1CNX Air Cleaner 3 Clogging Monitor Panel E01 Mechanical system 40-156
AA1DNX Air Cleaner 4 Clogging Monitor Panel E01 Mechanical system 40-158
AB00L6 Discharge of alternator R terminal Monitor Panel E01 Electrical system 40-160
WA1200-6 40-27
Failure codes table
Values marked A: See Cummins shop manual.

Reference
code charge code
page
AB00MA Discharge of alternator R terminal Monitor Panel E03 Electrical system 40-162
AB00MB Discharge of alternator R terminal KOMTRAX Plus E03 Electrical system 40-164
B@BCZK Drop in Engine Coolant Level Monitor Panel E01 Mechanical system 40-166
b@C5ZK Low brake fluid level(before engine start) KOMTRAX Plus E01 Mechanical system 40-168
B@C5ZK Low brake fluid level(while engine is running) KOMTRAX Plus E03 Mechanical system 40-169
B@C6NS High brake oil temp. Monitor Panel E02 Mechanical system 40-170
b@CENS High torque converter oil temp. Monitor Panel E02 Mechanical system 40-171
B@CENS Very high torque converter oil temp. Monitor Panel E02 Mechanical system 40-172
B@GAZK Low battery 1 fluid level KOMTRAX Plus E01 Mechanical system 40-174
B@GBZK Low battery 2 fluid level KOMTRAX Plus E01 Mechanical system 40-176
B@GCZK Low battery 3 fluid level KOMTRAX Plus E01 Mechanical system 40-178
B@HANS High hydraulic oil temp. Monitor Panel E02 Mechanical system 40-180
B@HAZK Low hydraulic oil level Monitor Panel E01 Mechanical system 40-181
Engine
CA115 Engine Speed Signal Lost E03 Mechanical system A
(Cummins)
Engine
CA135 Oil pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA141 Oil pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA144 Coolant temp. sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA145 Coolant temp. sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA146 High coolant temp. E02 Mechanical system A
(Cummins)
Engine
CA151 High coolant temp. Most severe level E02 Mechanical system A
(Cummins)
Intake temp. sensor circuit failed High - Left Engine
CA153 E01 Electrical system A
Bank Front (Cummins)
Intake temp. sensor circuit failed Low - Left Engine
High intake temp. - Left Bank Front Most severe Engine
CA155 E02 Mechanical system A
level (Cummins)
Intake temp. sensor circuit failed High - Right Engine
Intake temp. sensor circuit failed Low - Right Engine
High intake temp. - Right Bank Front Most Engine
severe level (Cummins)
Intake temp. sensor circuit failed High - Left Engine
Bank Rear (Cummins)
Intake temp. sensor circuit failed Low - Left Engine
Bank Rear (Cummins)
High intake temp. - Left Bank Rear Most severe Engine
level (Cummins)
Intake temp. sensor circuit failed High - Right Engine
Bank Rear (Cummins)
Intake temp. sensor circuit failed Low - Right Engine
Bank Rear (Cummins)
High intake temp. - Right Bank Rear Most Engine
severe level (Cummins)
Engine
CA187 Sensor supply 2 circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA212 Engine oil temp. sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA213 Engine oil temp. sensor circuit failed Low E01 Electrical system A
(Cummins)
40-28 WA1200-6
Failure codes table

Reference
code charge code
page
Engine
CA214 High Engine Oil Temp. Most severe level E02 Mechanical system A
(Cummins)
Engine
CA221 Ambient Air Pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA222 Ambient Air Pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA227 Sensor supply 2 circuit failed High E01 Electrical system A
(Cummins)
Engine
CA228 Low coolant pressure. Most severe level E03 Electrical system A
(Cummins)
Engine
CA231 Coolant pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA232 Coolant pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA234 Engine overspeed E03 Mechanical system A
(Cummins)
Engine
(Cummins)
Engine
CA261 High fuel temp. E02 Mechanical system A
(Cummins)
Engine
CA263 Fuel temp. sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA265 Fuel temp. sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA266 High fuel temp. Most severe level E03 Mechanical system A
(Cummins)
Engine
CA271 Fuel pump pressurizing circuit failed Low E01 Mechanical system A
(Cummins)
Engine
CA272 Fuel pump pressurizing circuit failed High E01 Mechanical system A
(Cummins)
Engine
CA285 Communication Lost (EMC) PGN Timeout Error E03 Electrical system A
(Cummins)
Engine
CA286 Communication Lost (EMC) Configuration Error E03 Electrical system A
(Cummins)
Engine
CA319 Real Time Clock Power Error – Mechanical system A
(Cummins)
Engine
CA323 Injector Solenoid Driver Cyl 5 circuit failed Low E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
CA342 Calibration Incompatibility Error E03 Mechanical system A
(Cummins)
Engine
CA343 ECM hardware failure E01 Mechanical system A
(Cummins)
Engine
CA349 AXG speed High error E01 Mechanical system A
(Cummins)
Engine
CA351 Injector Power Supply failed Low E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CA415 Low oil pressure. Most severe level E03 Mechanical system A
(Cummins)
Engine
CA418 Water in fuel least severe level – Mechanical system A
(Cummins)
Engine
CA421 High Engine Oil Temp. E02 Mechanical system A
(Cummins)
Engine
CA431 Idle Validation Invalid E01 Mechanical system A
(Cummins)
WA1200-6 40-29
Failure codes table

Reference
code charge code
page
Engine
CA441 Low Battery Voltage E01 Electrical system A
(Cummins)
Engine
CA442 High Battery Voltage E01 Electrical system A
(Cummins)
Engine
CA449 High common rail pressure Most severe level E03 Mechanical system A
(Cummins)
Engine
CA451 Fuel rail pressure circuit failed High E01 Electrical system A
(Cummins)
Engine
CA452 Fuel rail pressure circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA488 High intake temp. - Left Bank Front E02 Mechanical system A
(Cummins)
Engine
CA489 AXG speed Low error E01 Mechanical system A
(Cummins)
Engine
CA546 Fuel pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA547 Fuel pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA556 High Crankcase Pressure Most severe level E03 Mechanical system A
(Cummins)
Engine
CA559 High fuel rail pressure E01 Mechanical system A
(Cummins)
Engine
CA611 Engine Hot Shutdown – Mechanical system A
(Cummins)
Engine
CA689 Engine crankshaft speed failed E01 Mechanical system A
(Cummins)
Engine speed misalignment Camshaft and Engine
Crankshaft (Cummins)
Rapid rise intake manifold temp. Left Bank Engine
Front (Cummins)
Engine
CA1117 Power Lost with Ignition On – Electrical system A
(Cummins)
Engine
CA1257 Module ID Input State Error E03 Electrical system A
(Cummins)
Engine
CA1358 Accelerator pedal sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA1359 Accelerator pedal sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA1363 Low intake manifold pressure Left bank Front E01 Mechanical system A
(Cummins)
Engine
CA1373 Ether solenoid circuit failed E01 Electrical system A
(Cummins)
Engine
CA1376 Engine camshaft speed failed – Mechanical system A
(Cummins)
Intake pressure sensor circuit failed High - Left Engine
Intake pressure sensor circuit failed Low - Left Engine
Engine
CA1542 Engine oil level sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA1543 Engine oil level sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA1544 Low engine oil level E01 Mechanical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
40-30 WA1200-6
Failure codes table

Reference
code charge code
page
Engine
(Cummins)
Engine
CA1638 Low intake manifold pressure Right bank Front E01 Mechanical system A
(Cummins)
Engine
CA1843 Crankcase pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CA1844 Crankcase pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CA1845 Water in fuel sensor circuit failed High E01 Mechanical system A
(Cummins)
Engine
CA1846 Water in fuel sensor circuit failed Low E01 Mechanical system A
(Cummins)
Engine
CA1852 Water in fuel E01 Mechanical system A
(Cummins)
Communication Lost (EMC) Remote Accelera- Engine
CA1889 – Electrical system A
tor Pedal (Cummins)
Engine
CA1911 High common rail pressure E01 Mechanical system A
(Cummins)
Engine
CA1984 High intake temp. - Right Bank Front E02 Mechanical system A
(Cummins)
Engine
CA1985 High intake temp. - Left Bank Rear E02 Mechanical system A
(Cummins)
Engine
CA1986 High intake temp. - Right Bank Rear E02 Mechanical system A
(Cummins)
Rapid rise intake manifold temp. Right Bank Engine
Front (Cummins)
Front (Cummins)
Rear (Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CA2215 Low fuel pump delivery pressure E01 Mechanical system A
(Cummins)
High fuel pump delivery pressure Least severe Engine
Level (Cummins)
Low fuel pump delivery pressure Least severe Engine
Level (Cummins)
Engine
CA2265 Lift Pump Supply Circuit failed High E01 Mechanical system A
(Cummins)
Engine
CA2266 Lift Pump Supply Circuit failed Low E01 Mechanical system A
(Cummins)
Engine
CA2311 Fuel injection control valve circuit failed E01 Mechanical system A
(Cummins)
Engine
CA2474 Turbocharger speed failed E01 Mechanical system A
(Cummins)
Engine
CA2697 Accelerator pedal Idle validation circuit failed E01 Mechanical system A
(Cummins)
Communication Lost (EMC) between Parent Engine
CA2727 – Mechanical system A
and Child (Cummins)
Engine
CA2734 Ether bottle empty E01 Mechanical system A
(Cummins)
Engine
CA2963 High engine coolant temp. Least severe level – Mechanical system A
(Cummins)
High Intake Manifold Temp. Left Bank Front - Engine
CA2964 – Mechanical system A
Least severe level (Cummins)
Engine
CB115 Engine Speed Signal Lost E03 Mechanical system A
(Cummins)
WA1200-6 40-31
Failure codes table

Reference
code charge code
page
Engine
CB187 Sensor supply 2 circuit failed Low E01 Electrical system A
(Cummins)
Engine
CB227 Sensor supply 2 circuit failed High E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
CB325 Injector Solenoid Driver Cyl 6 circuit failed Low E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
CB342 Calibration Incompatibility Error E03 Mechanical system A
(Cummins)
Engine
CB343 ECM hardware failure E01 Mechanical system A
(Cummins)
Engine
CB351 Injector Power Supply failed Low E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CB441 Low Battery Voltage E01 Electrical system A
(Cummins)
Engine
CB442 High Battery Voltage E01 Electrical system A
(Cummins)
Engine
CB621 Low Exhaust Temp. Left Bank #1 E01 Mechanical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CB631 Low Exhaust Temp. Right Bank #1 E01 Mechanical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CB689 Engine crankshaft speed failed E01 Mechanical system A
(Cummins)
Exhaust Temp. sensor circuit failed low Right Engine
CB721 – Electrical system A
Bank #1 (Cummins)
40-32 WA1200-6
Failure codes table

Reference
code charge code
page
Bank #2 (Cummins)
Bank #3 (Cummins)
Bank #4 (Cummins)
Bank #5 (Cummins)
Bank #6 (Cummins)
Bank #7 (Cummins)
Bank #8 (Cummins)
CB731 E01 Mechanical system A
Engine
CB1117 Power Lost with Ignition On – Electrical system A
(Cummins)
Engine
CB1257 Module ID Input State Error E03 Electrical system A
(Cummins)
Engine
CB1362 Engine oil filter clogging E01 Mechanical system A
(Cummins)
Engine
CB1367 Pre oil filter pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CB1368 Pre oil filter pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Engine
CB1376 Engine camshaft speed failed – Mechanical system A
(Cummins)
Engine
CB1377 Post oil filter pressure sensor circuit failed High E01 Electrical system A
(Cummins)
Engine
CB1378 Post oil filter pressure sensor circuit failed Low E01 Electrical system A
(Cummins)
Intake pressure sensor circuit failed High - Right Engine
CB1385 E01 Electrical system A
Intake pressure sensor circuit failed Low - Right Engine
CB1386 E01 Electrical system A
Exhaust temp. sensor circuit failed High - Right Engine
Bank #1 (Cummins)
Bank #3 (Cummins)
Bank #4 (Cummins)
Bank #5 (Cummins)
Bank #6 (Cummins)
Bank #7 (Cummins)
Bank #8 (Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Bank #2 (Cummins)
Engine
(Cummins)
WA1200-6 40-33
Failure codes table

Reference
code charge code
page
Engine
CB2121 High exhaust temp. Left Bank #1 E01 Mechanical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CB2131 High exhaust temp. Right Bank #1 E01 Mechanical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CC115 Engine Speed Signal Lost E03 Mechanical system A
(Cummins)
Engine
CC187 Sensor supply 2 circuit failed Low E01 Electrical system A
(Cummins)
Engine
CC227 Sensor supply 2 circuit failed High E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
CC322 Injector Solenoid Driver Cyl 1 circuit failed Low E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
CC342 Calibration Incompatibility Error E03 Mechanical system A
(Cummins)
Engine
CC343 ECM hardware failure E01 Mechanical system A
(Cummins)
Engine
CC351 Injector Power Supply failed Low E01 Electrical system A
(Cummins)
Engine
(Cummins)
Engine
(Cummins)
Engine
CC441 Low Battery Voltage E01 Electrical system A
(Cummins)
40-34 WA1200-6
Failure codes table

Reference
code charge code
page
Engine
CC442 High Battery Voltage E01 Electrical system A
(Cummins)
Exhaust Temp. sensor circuit failed low Left Engine
CC671 – Electrical system A
Bank #1 (Cummins)
Bank #2 (Cummins)
Bank #3 (Cummins)
Bank #4 (Cummins)
Bank #5 (Cummins)
Bank #6 (Cummins)
Bank #7 (Cummins)
Bank #8 (Cummins)
Engine
CC689 Engine crankshaft speed failed E01 Mechanical system A
(Cummins)
CC731 E01 Mechanical system A
Engine
CC1117 Power Lost with Ignition On – Electrical system A
(Cummins)
Engine
CC1257 Module ID Input State Error E03 Electrical system A
(Cummins)
Engine
CC1376 Engine camshaft speed failed – Mechanical system A
(Cummins)
Exhaust temp. sensor circuit failed High - Left Engine
Bank #2 (Cummins)
Bank #3 (Cummins)
Bank #4 (Cummins)
Bank #5 (Cummins)
Bank #6 (Cummins)
Bank #7 (Cummins)
Bank #8 (Cummins)
Engine
(Cummins)
Engine
(Cummins)
Bank #1 (Cummins)
Engine
(Cummins)
Engine
(Cummins)
Boom Bucket &
D191KA Neutral Output Relay Disconnection E01 Electrical system 40-182
AJSS
Boom Bucket &
D191KB Neutral Output Relay hot short E01 Electrical system 40-184
AJSS
WA1200-6 40-35
Failure codes table
Reference
code charge code
page
SW pump PNC solenoid Relay (Discon- Boom Bucket &
D19MKA E01 Electrical system 40-186
nect/Short Circuit) AJSS
Boom Bucket &
D19MKY SW pump PNC solenoid Relay hot short E01 Electrical system 40-188
AJSS
Boom Bucket &
D19MMA SW pump PNC solenoid circuit 1 Failure E01 Electrical system 40-190
AJSS
Boom Bucket &
D19MMB SW pump PNC solenoid circuit 2 Failure E01 Electrical system 40-192
AJSS
Starting Switch C signal circuit (Discon-
D5ZHKA Transmission E01 Electrical system 40-193
nect/Short Circuit)
D5ZHKB Starting Switch C signal circuit Hot short Transmission E01 Electrical system 40-195
Boom Bucket &
D5ZHKZ Strarting Switch C signal circuit failure E01 Electrical system 40-197
AJSS
D5ZHL6 Ignition C terminal Circuit Failure Monitor Panel E01 Electrical system 40-199
DAF5KP Monitor Panel 5 V source sys Error Monitor Panel E01 Electrical system 40-202
DAFRKR Communication Lost Monitor Panel Controller Transmission E03 Electrical system 40-204
Drop in Transmission Controller Main Power
DAQ0KK Transmission E03 Electrical system 40-206
Source
DAQ0KT Nonvolatile Memory Writing Data Abnormal Transmission E01 Electrical system 40-208
Drop in Transmission Controller Solenoid
DAQ2KK Transmission E03 Electrical system 40-210
Power Source
DAQRKR Communication Lost T/M Controller Monitor Panel E03 Electrical system 40-212
Defective Option Selection Data in Transmis-
DAQRMA Transmission E03 Mechanical system 40-214
sion
DB2RKR Communication Lost Engine Controller Transmission E03 Electrical system 40-216
Boom Bucket &
DB90KK Drop in Work Controller Main Power Source E03 Electrical system 40-218
AJSS
Boom Bucket &
DB90KT Nonvolatile Memory Writing Data Abnormal E01 Electrical system 40-220
AJSS
Boom Bucket &
DB92KK Solenoid Voltage Failure (Work controller) E03 Electrical system 40-222
AJSS
Boom Bucket &
DB95KX 5 V source sys Error (Work controller) E03 Electrical system 40-224
AJSS
Communication Lost Boom Bucket & Joy stick
DB9RKR Transmission E03 Electrical system 40-226
Controller
Defective Option Selection Data in Boom Boom Bucket &
DB9RMA E03 Mechanical system 40-228
Bucket Controller AJSS
Boom Bucket &
DB9RMC Communication Lost (Work Controller) E03 Electrical system 40-230
AJSS
DBB0KK VHMS source voltage Error KOMTRAX Plus E03 Electrical system 40-232
DBB0KQ VHMS Connector Mismatch KOMTRAX Plus E03 Mechanical system 40-234
Abnormality in VBAT voltage(VHMS
DBB3KK KOMTRAX Plus E03 Electrical system 40-236
VBAT<10V)
DBB5KP VHMS 5 V source sys Error KOMTRAX Plus E01 Electrical system 40-238
DBBQMC Communication Lost (VHMS CAN0) KOMTRAX Plus E03 Electrical system 40-237
DBBRKR Communication Lost VHMS Controller Monitor Panel E03 Electrical system 40-239
40-36 WA1200-6
Failure codes table
Reference
code charge code
page
DBBRMC Communication Lost (VHMS CAN1) KOMTRAX Plus E03 Electrical system 40-240
DD10KX Verification Mode SW Failure Transmission E01 Mechanical system 40-242

Boom Bucket &
DD1ALD Remote positioner upper side set sw failure E01 Electrical system 40-243
AJSS
Boom Bucket &
DD1BLD Remote positioner lower side set sw failure E01 Electrical system 40-245
AJSS
DDA7L4 Throttle Lock Input signal Short Circuit Transmission E01 Electrical system 40-254
Throttle Lock (set/accelerator) switch Short Cir-
DDA8KB Transmission E01 Electrical system 40-256
cuit
Throttle Lock (set/decelerator) switch Short Cir-
DDA9KB Transmission E01 Electrical system 40-258
cuit
DDB6L4 Neutral Signal Malfunction Transmission E03 Electrical system 40-260
DDD7KA Speed control dial circuit (Low Voltage) Transmission E01 Electrical system 40-262
DDD7KB Speed control dial circuit (High Voltage) Transmission E01 Electrical system 40-264
DDDBKA Traction control dial circuit (Low Voltage) Transmission E01 Electrical system 40-266
DDDBKB Traction control dial circuit (High Voltage) Transmission E01 Electrical system 40-268
DDE5MA Emergency steering signal Failure Monitor Panel E01 Electrical system 40-270
DDK4KA AJSS F/N/R Input Signal Disconnection Transmission E03 Electrical system 40-272
DDK4KB AJSS F/N/R Input Signal Short Circuit Transmission E03 Electrical system 40-274
Joystick Shift up/down SW circuit (Discon-
DDK5L4 Transmission E01 Electrical system 40-276
nect/Short Circuit)
Steering lock detector pressure switch signal
DDP5KA Transmission E01 Electrical system 40-278
circuit Disconnect
DDT4LD T/M Cut Off set switch signal short circuit Transmission E01 Electrical system 40-280
DDW9LD Kickdown Switch Short Circuit Transmission E01 Electrical system 40-282
DGE5KX Ambient air temp Sensor Failure KOMTRAX Plus E01 Electrical system 40-284
Transmission Oil Temperature sensor signal
DGF1KA Transmission E01 Electrical system 40-286
Disconnect
Abnormality in Transmission Oil Temperature
DGF1KB Transmission E01 Electrical system 40-288
sensor Short Circuit
Transmission Oil Temperature sensor Failure
DGF1KX Transmission E01 Electrical system 40-281
(For Check)
DGH2KX Hydraulic oil temp. sensor circuit failure Monitor Panel E01 Electrical system 40-283
DGR2KA Brake oil temp. sensor circuit Disconnection Monitor Panel E01 Electrical system 40-284
DGR2KX Brake oil temp. sensor circuit failure Monitor Panel E01 Electrical system 40-286
DGT1KX T/C oil temp. sensor circuit failure Monitor Panel E01 Electrical system 40-288
DH20KX Torque converter pressure sensor circuit KOMTRAX Plus E01 Electrical system 40-300
Loader pump oil press sensor (Discon- Boom Bucket &
DH21KA E01 Electrical system 40-302
Boom Bucket &
DH21KB Loader pump oil press sensor hot short E01 Electrical system 40-304
AJSS
Boom Bucket &
DHPCKA Boom bottom press. (Disconnect/Short Circuit) E01 Electrical system 40-306
AJSS
DHPCKX Boom bottom press. sensor circuit failure Monitor Panel E01 Electrical system 40-308
WA1200-6 40-37
Failure codes table
Reference
code charge code
page
Boom Bucket &
DHPCKY Boom bottom press. hot short E01 Electrical system 40-310
AJSS
DHPDKX Boom head press. sensor circuit failure Monitor Panel E01 Electrical system 40-312
DHT1KX T/M Cut Off pressure sensor signal Disconnect T/M E01 Electrical system 40-314
DHT2L6 T/M oil filter sensor circuit failure Monitor Panel E01 Electrical system 40-316
DHT3KX Transmission main pressure sensor circuit KOMTRAX Plus E01 Electrical system 40-318
DHT4KX Main PPC oil pressure sensor circuit KOMTRAX Plus E01 Electrical system 40-320
DHT5KX Torque converter intake pressure sensor circuit KOMTRAX Plus E01 Electrical system 40-322
DHT8KX Steering Oil Press. Sensor Failure KOMTRAX Plus E01 Electrical system 40-324
Transmission lubrication pressure sensor cir-
DHTAKX KOMTRAX Plus E01 Electrical system 40-326
cuit
Modulation clutch pressure sensor circuit Dis-
DHTBKA Transmission E03 Electrical system 40-328
connect
Modulation clutch pressure sensor signal short
DHTBKB Transmission E03 Electrical system 40-330
circuit
DHU2KA F Brake Oil press Sensor Disconnect Transmission E01 Electrical system 40-332
DHU2KB F Brake Oil press Sensor Hot short Transmission E01 Electrical system 40-334
DHU2KX F Brake Oil press Sensor Failure KOMTRAX Plus E01 Electrical system 40-336
DHU3KA R Brake Oil press Sensor Disconnect Transmission E01 Electrical system 40-338
DHU3KB R Brake Oil press Sensor Hot short Transmission E01 Electrical system 40-325
DHU3KX R Brake Oil press Sensor Failure KOMTRAX Plus E01 Electrical system 40-326
DJF1KA Fuel level sensor circuit Disconnection Monitor Panel E01 Electrical system 40-328
Steering lever angle sensor (Disconnect/Short Boom Bucket &
DK30KA E01 Electrical system 40-329
Circuit) AJSS
Boom Bucket &
DK30KY Steering lever angle sensor circuit hot short E01 Electrical system 40-330
AJSS
Boom lever potentiometer (main) (Discon- Boom Bucket &
DK59KA E03 Electrical system 40-331
Boom Bucket &
DK59KY Boom lever potentiometer (main) hot short E03 Electrical system 40-333
AJSS
Boom Bucket &
DK59L8 Boom lever potentiometer (main & sub) failure E03 Mechanical system 40-349
AJSS
Boom lever potentiometer (sub) (Discon- Boom Bucket &
DK5AKA E03 Electrical system 40-352
Boom Bucket &
DK5AKY Boom lever potentiometer (sub) hot short E03 Electrical system 40-354
AJSS
Bucket lever potentiometer (main) (Discon- Boom Bucket &
DK5BKA E03 Electrical system 40-356
Boom Bucket &
DK5BKY Bucket lever potentiometer (main) hot short E03 Electrical system 40-358
AJSS
Boom Bucket &
DK5BL8 Bucket lever potentiometer (main & sub) failure E03 Mechanical system 40-359
AJSS
Bucket lever potentiometer (sub) (Discon- Boom Bucket &
DK5CKA E03 Electrical system 40-362
Boom Bucket &
DK5CKY Bucket lever potentiometer (sub) hot short E03 Electrical system 40-363
AJSS
Boom Bucket &
DKA0KA Boom angle sensor (Disconnect/Short Circuit) E01 Electrical system 40-364
AJSS
40-38 WA1200-6
Failure codes table
Values marked *: "E-POCV" on monitor screen refers to "ECMV"

Reference
code charge code
page
Boom Bucket &
DKA0KX Boom angle sensor circuit failure E01 Electrical system 40-366
AJSS
Boom Bucket &
DKA0KY Boom angle sensor circuit hot short E01 Electrical system 40-368
AJSS
Boom Bucket &
DKA0L0 Boom angle sensor failure E01 Mechanical system 40-370
AJSS
Boom Bucket &
DKD0KA Frame angle sensor (Disconnect/Short Circuit) E01 Electrical system 40-372
AJSS
Boom Bucket &
DKD0KY Frame angle sensor circuit hot short E01 Electrical system 40-373
AJSS
Boom Bucket &
DKD0KZ Frame and steering angle sensor failure E01 Mechanical system 40-374
AJSS
DKH0KA Angle sensor circuit(FR) Disconnect Transmission E01 Electrical system 40-375
DKH0KB Angle sensor circuit(FR) Hot short Transmission E01 Electrical system 40-360
DKH1KA Angle sensor circuit(LR) Disconnect Transmission E01 Electrical system 40-361
DKH1KB Angle sensor circuit(LR) Hot short Transmission E01 Electrical system 40-363
DLE2KA Engine Speed Sensor Disconnection Transmission E03 Electrical system 40-364
DLE2LC Engine Speed Sensor Short Circuit Transmission E03 Electrical system 40-366
DLF6LC Tire speed sensor circuit Transmission E01 Electrical system 40-386
DLFAKA Mod/c Output Speed Sensor Disconnect Transmission E03 Electrical system 40-388
DLFALC Mod/c Output Speed Sensor Short Circuit Transmission E03 Electrical system 40-390
DLT4KB Output Shaft Speed Sensor (1) Short Circuit Transmission E03 Electrical system 40-392
DLT4KX Output Shaft Speed Sensor (1) Disconnection Transmission E03 Electrical system 40-394
Transmission cut off indicator Output short cir-
DT20KB Transmission E01 Electrical system 40-396
cuit
DT21KB Speed Control indicator Output short circuit Transmission E01 Electrical system 40-397
DUM8KB VHMS Operation lamp Short Circuit KOMTRAX Plus E01 Electrical system 40-398
DV00KY Buzzer circuit hotshort(for usually) Monitor Panel E01 Electrical system 40-400
DV01KY Buzzer circuit hotshort(for special) Monitor Panel E01 Electrical system 40-402
T/M E-POCV (F bypass) Solenoid Disconnec-
DW23KA Transmission E03 Electrical system 40-404
tion (*)
T/M E-POCV (F bypass) Solenoid Short Cir-
DW23KB Transmission E03 Electrical system 40-387
cuit(*)
T/M E-POCV (F bypass) Solenoid circuit Hot
DW23KY Transmission E03 Electrical system 40-388
short (*)
T/M E-POCV (R bypass) Solenoid Disconnec-
tion (*)
T/M E-POCV (R bypass) Solenoid Short Circuit
(*)
T/M E-POCV (R bypass) Solenoid circuit Hot
short (*)
T/M E-POCV (1st bypass) Solenoid Disconnec-
tion (*)
T/M E-POCV (1st bypass) Solenoid Short Cir-
cuit (*)
T/M E-POCV (1st bypass) Solenoid circuit Hot
short (*)
WA1200-6 40-39
Failure codes table

Reference
code charge code
page
Boom Bucket &
DW4PKA Boom EPC solenoid (raise1) disconnection E03 Electrical system 40-413
AJSS
Boom Bucket &
DW4PKB Boom EPC solenoid (raise1) short circuit E03 Electrical system 40-414
AJSS
Boom Bucket &
DW4PKY Boom EPC solenoid (raise1) hot short E03 Electrical system 40-415
AJSS
Boom Bucket &
DW4QKA Boom EPC solenoid (take down1) disconnection E03 Electrical system 40-416
AJSS
Boom Bucket &
DW4QKB Boom EPC solenoid (take down1) short circuit E03 Electrical system 40-417
AJSS
Boom Bucket &
DW4QKY Boom EPC solenoid (take down1) hot short E03 Electrical system 40-400
AJSS
Boom Bucket &
DW4RKA Bucket tilt1 EPC solenoid disconnection E03 Electrical system 40-401
AJSS
Boom Bucket &
DW4RKB Bucket tilt1 EPC solenoid short circuit E03 Electrical system 40-402
AJSS
Boom Bucket &
DW4RKY Bucket tilt1 EPC solenoid hot short E03 Electrical system 40-403
AJSS
Boom Bucket &
DW4SKA Bucket dump1 EPC solenoid disconnection E03 Electrical system 40-404
AJSS
Boom Bucket &
DW4SKB Bucket dump1 EPC solenoid short circuit E03 Electrical system 40-405
AJSS
Boom Bucket &
DW4SKY Bucket dump1 EPC solenoid hot short E03 Electrical system 40-406
AJSS
Boom Bucket &
DW5PKA Boom EPC solenoid (raise2) disconnection E03 Electrical system 40-407
AJSS
Boom Bucket &
DW5PKB Boom EPC solenoid (raise2) short circuit E03 Electrical system 40-408
AJSS
Boom Bucket &
DW5PKY Boom EPC solenoid (raise2) hot short E03 Electrical system 40-409
AJSS
Boom Bucket &
DW5QKA Boom EPC solenoid (take down2) disconnection E03 Electrical system 40-410
AJSS
Boom Bucket &
DW5QKB Boom EPC solenoid (take down2) short circuit E03 Electrical system 40-411
AJSS
Boom Bucket &
DW5QKY Boom EPC solenoid (take down2) hot short E03 Electrical system 40-412
AJSS
Boom Bucket &
DW5RKA Bucket tilt2 EPC solenoid disconnection E03 Electrical system 40-431
AJSS
Boom Bucket &
DW5RKB Bucket tilt2 EPC solenoid short circuit E03 Electrical system 40-432
AJSS
Boom Bucket &
DW5RKY Bucket tilt2 EPC solenoid hot short E03 Electrical system 40-433
AJSS
Boom Bucket &
DW5SKA Bucket dump2 EPC solenoid disconnection E03 Electrical system 40-434
AJSS
Boom Bucket &
DW5SKB Bucket dump2 EPC solenoid short circuit E03 Electrical system 40-435
AJSS
Boom Bucket &
DW5SKY Bucket dump2 EPC solenoid hot short E03 Electrical system 40-436
AJSS
T/M E-POCV (R drain) Solenoid Disconnection
DWJ2KA Transmission E03 Electrical system 40-437
(*)
DWJ2KB T/M E-POCV (R drain) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-438
T/M E-POCV (R drain) Solenoid circuit Hot short
DWJ2KY Transmission E03 Electrical system 40-439
(*)
Work equipment neutral lock solenoid discon- Boom Bucket &
DWM1KA E01 Electrical system 40-440
nection AJSS
Work equipment neutral lock solenoid short cir- Boom Bucket &
DWM1KB E01 Electrical system 40-441
cuit AJSS
Boom Bucket &
DWM1KY Work equipment neutral lock solenoid hot short E01 Electrical system 40-428
AJSS
40-40 WA1200-6
Failure codes table

Reference
code charge code
page
Magnet detent solenoid (Boom raise) discon- Boom Bucket &
DWN6KA E01 Electrical system 40-430
nection AJSS
Magnet detent solenoid (Boom raise) short cir- Boom Bucket &
DWN6KB E01 Electrical system 40-432
cuit AJSS
Boom Bucket &
DWN6KY Magnet detent solenoid (Boom raise) hot short E01 Electrical system 40-434
AJSS
Magnet detent solenoid (Boom float) disconnec- Boom Bucket &
tion AJSS
Magnet detent solenoid (Boom float) short cir- Boom Bucket &
DWN7KB E01 Electrical system 40-438
cuit AJSS
Boom Bucket &
DWN7KY Magnet detent solenoid (Boom float) hot short E01 Electrical system 40-440
AJSS
Magnet detent solenoid (Bucket tilt) disconnec- Boom Bucket &
tion AJSS
Boom Bucket &
DWN8KB Magnet detent solenoid (Boom tilt) short circuit E01 Electrical system 40-444
AJSS
Boom Bucket &
DWN8KY Magnet detent solenoid (Boom tilt) hot short E01 Electrical system 40-446
AJSS
Boom Bucket &
DWNAKA NC solenoid disconnection E01 Electrical system 40-452
AJSS
Boom Bucket &
DWNAKB NC solenoid short circuit E01 Electrical system 40-453
AJSS
Boom Bucket &
DWNAKY NC solenoid hot short E01 Electrical system 40-454
AJSS
Loader pump solenoid Relay (Disconnect/Short Boom Bucket &
DXA1KA E01 Electrical system 40-455
Circuit) AJSS
Boom Bucket &
DXA1KY Loader pump solenoid Relay hot short E01 Electrical system 40-457
AJSS
Loader pump solenoid Relay (Disconnect/Short Boom Bucket &
DXA1MA E01 Electrical system 40-459
Circuit) AJSS
Boom Bucket &
DXF0KA AJSS EPC solenoid disconnection E03 Electrical system 40-461
AJSS
Boom Bucket &
DXF0KB AJSS EPC solenoid short circuit E03 Electrical system 40-463
AJSS
DXH4KA T/M E-POCV (1st) Solenoid Disconnection (*) Transmission E03 Electrical system 40-465
DXH4KB T/M E-POCV (1st) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-467
DXH4KY T/M E-POCV (1st) Solenoid circuit Hot short (*) Transmission E03 Electrical system 40-469
DXH5KA T/M E-POCV (2nd) Solenoid Disconnection (*) Transmission E03 Electrical system 40-471
DXH5KB T/M E-POCV (2nd) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-473
DXH5KY T/M E-POCV (2nd) Solenoid circuit Hot short (*) Transmission E03 Electrical system 40-475
DXH6KA T/M E-POCV (3rd) Solenoid Disconnection (*) Transmission E03 Electrical system 40-477
DXH6KB T/M E-POCV (3rd) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-479
DXH6KY T/M E-POCV (3rd) Solenoid circuit Hot short (*) Transmission E03 Electrical system 40-481
DXH7KA T/M E-POCV (R) Solenoid Disconnection (*) Transmission E03 Electrical system 40-483
DXH7KB T/M E-POCV (R) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-485
DXH7KY T/M E-POCV (R) Solenoid circuit Hot short (*) Transmission E03 Electrical system 40-487
DXH8KA T/M E-POCV (F) Solenoid Disconnection (*) Transmission E03 Electrical system 40-489
DXH8KB T/M E-POCV (F) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-491
WA1200-6 40-41
Failure codes table

Reference
code charge code
page
DXH8KY T/M E-POCV (F) Solenoid circuit Hot short (*) Transmission E03 Electrical system 40-493
T/M E-POCV (MOD/C) Solenoid Disconnection
DXHPKA Transmission E03 Electrical system 40-494
(*)
DXHPKB T/M E-POCV (MOD/C) Solenoid Short Circuit (*) Transmission E03 Electrical system 40-495
T/M E-POCV (MOD/C) Solenoid Short Circuit to
DXHPKY Transmission E03 Electrical system 40-496
24 V (*)
DXHPMA T/M E-POCV (MOD/C) Solenoid Malfunction (*) Transmission E01 Electrical system 40-497
a The items in this table are arranged in the order of the failure codes.
a Applicable component is a controller or the machine monitor in charge of the system check.
a The failure codes that do not have numbers in the action code columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the abnormality record.
(For details, see "Troubleshooting by failure code (Display of code)".)
40-42 WA1200-6
Symptom and troubleshooting numbers
Symptom and troubleshooting numbers 40-43
Troubleshooting
No. Symptom of failure
Index Page
Action code/Failure code
1 Action code and failure code are displayed on machine monitor.
Perform troubleshooting for failure
2 Failure code is displayed on mechanical system abnormality record.
code
3 Failure code is displayed on electrical system abnormality record.
Symptom related to work equipment, steering, travel
4 Torque converter oil temperature rises too high (overheating). H-1 40-702
5 Turning or response of steering is poor. H-2 40-705
6 AJSS lever is hard to operate. H-3 40-708
7 Steering shakes or jolts. H-4 40-710
8 Wheel brake does not work at all or is weak. H-5 40-712
9 Lift arm speed is low or lift arm rising force is insufficient. H-6 40-714
10 Shock is large when lift arm stops. H-7 40-717
11 Hydraulic oil temperature rises too high (overheating). H-8 40-718
Symptom related to monitor
12 Machine monitor does not operate. E-3 40-501
Service meter does not proceed, or service meter proceeds while engine
13 E-9 40-512
stopped.
14 Buzzer operated by monitor panel controller does not sound. E-10 40-514
Symptom related other electrical system
15 LED for remote positioner "RAISE" or "LOWER" does not light up. E-1 40-499
16 Open circuit or ground fault in check lamp system. E-2 40-500
17 Turn signal lamp does not light up. E-4 40-502
18 Defective parking lamp. E-5 40-504
19 Defective front working lamp. E-6 40-506
20 Defective rear working lamp. E-7 40-508
21 Night lighting does not light up. E-8 40-510
22 Defective auto-greasing system. E-11 40-516
WA1200-6 40-43
Information in troubleshooting table
Information in troubleshooting table 40-4

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
User code Failure code
Display on Failure name displayed on the Abnormality Record screen of the
Display on machine Failure
machine moni- machine monitor
monitor
tor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of
Action to be taken to protect the system and equipment when the machine monitor or controller detects
machine moni-
a trouble
tor or controller
Problem on
Problem that appears on machine as result of action (above) taken by machine monitor or controller
machine
Related infor-
Information related to detected failure or troubleshooting
mation
Cause Procedure, measuring location, criteria and remarks
<Details of description>
q Procedure
q Measuring location
1 Defective component a "Between A and B" means the measurement of voltage, resistance or oth-
ers between terminals A and B.
q Criteria to judge probable causes (normal value)
q Remarks for judgment
<How to use troubleshooting sheet>
Open or short circuit in wiring q Perform troubleshooting procedures in numerical order.
2 q If the check result does not meet the criteria, the probable cause described
harness
on the left column is the actual cause of the failure.
q If the check result shows no abnormality, and unless otherwise specified, pro-
ceed to the next step (next cause item).
q Check that the failure is fixed after a failure was found and repaired.
Open circuit in wiring harness <Failures in wiring harness>
3 (wire breakage or defective con- q Open circuit in wiring
tact of connector) The connector connection is defective or the wire is broken.
q Ground fault
A harness not connected to ground circuit contacts the ground wiring or
machine.
q Hot short circuit
Ground fault in wiring harness A wiring harness not connected to the power supply circuit (24 V) contacts
4
(contact with ground circuit) with the power supply circuit.
q Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
<Precautions for troubleshooting>
Hot short circuit (1) Connector number indication method and handling of T-adapter
5
(contact with 24 V circuit) For troubleshooting, insert or connect T-adapter as follows unless otherwise
specified.
q When "male" or "female" is not indicated with a connector number, dis-
connect the connector, and insert T-adapter between the male and fe-
male connectors.
q When "male" or "female" is indicated with a connector number, discon-
6 Short circuit in wiring harness
nect the connector, and connect T-adapter only to either male or femae
connector.
(2) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads as shown
below unless otherwise specified.
q Connect the positive (+) lead to pin or wire indicated first.
7 Defective controller q Connect the negative (-) lead to a pin or wire indicated second.
40-44 WA1200-6
Information in troubleshooting table
Related circuit diagram 40-45
This is the excerpted circuit diagram related to trouble-

shooting
q The circuit diagram contains the connector Nos., pin
Nos., and connector colors related to the failure.
q The circuit diagram contains the destination or source of
the branch line in a wiring harness.
q Arrow (io): Roughly shows the location on the ma-
chine.
q NO: Normally Open
q NC: Normally Closed
WA1200-6 40-45
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Troubleshooting method for open circuit in wiring harness of pressure

sensor system 40-46
a Since pressure sensors consisting not only of resistors but also electronic circuit components such as am-
plifiers have variation in measured value and its own polarities. So troubleshooting must be performed
carefully.
Failure codes applicable to this diagnosis

q CA222: Ambient pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polaritied match these of the sensor.
a If measured value is infinite, take measurements by applying the probes of opposite polarities and
record the finite value obtained as a measured value.
a Since measured values may be dispersed, take several measurements. Cause of this dispersion
appears to be a charge in a sensor. Repeat steps 1 and 2 several times. Consider this dipersion
when judging whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine controller
connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on engine controller side,
and connect T-adapter (4) to the harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit

a "Apparent difference" means a difference of 10 or more times.
If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, "wiring harness is open".
40-46 WA1200-6
Troubleshooting method for open circuit in wiring harness of pressure sensor system
List of pressure sensor measuring locations and reference values

Measured internal resistance of
Measuring location at
Sensor sensor Remarks
sensor pin
(Reference value)
Sensor is common to engine mod-
R2: Between (1) and (3) Approx. 3.2 kz
els 95, 125, 140, 170 and 12 V140
Ambient pressure R1: Between (2) (+) and
Approx. 4.6 kz
sensor (1) (-) If polarities are reversed, resis-
R1: Between (1) (+) and tance value changes.
Approx. 2.9 kz
(2) (-)
*: In addition to the above, when measuring R2', disconnect the following:(See circuit diagram related to fail-
ure code CA187)
q When measuring R2' of ambient pressure sensor (CA222):
Connectors of charge pressure sensor, resistance RES, engine oil pressure sensor, G sensor, EGR valve
lift sensor and bypass valve lift sensor
Measurement record (For measuring locations, see circuit diagram related to failure code CA222)
Sensor + Wiring harness
Sensor unit (Measuring
(Measuring location on
Sensor location on sensor pin Measured value Measured value
harness side connector
side connector)
of engine controller)
R2': Between (37) and
R2: Between (1) and (3)
(38) (*)
Ambient pressure R1: Between (2) (+) and R1': Between (3) (+)
sensor (1) (-) and (38) (-)
R1: Between (1) (+) and R1': Between (38) (+)
(2) (-) and (3) (-)
WA1200-6 40-47
Layout drawing of connector pins
Layout drawing of connector pins 40-48

(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-48 WA1200-6
WA1200-6 40-49
40-50 WA1200-6
WA1200-6 40-51
40-52 WA1200-6
WA1200-6 40-53
40-54 WA1200-6
WA1200-6 40-55
40-56 WA1200-6
WA1200-6 40-57
40-58 WA1200-6
WA1200-6 40-59
40-60 WA1200-6
WA1200-6 40-61
40-62 WA1200-6
WA1200-6 40-63
40-64 WA1200-6
WA1200-6 40-65
40-66 WA1200-6
WA1200-6 40-67
40-68 WA1200-6
WA1200-6 40-69
40-70 WA1200-6
WA1200-6 40-71
40-72 WA1200-6
WA1200-6 40-73
40-74 WA1200-6
WA1200-6 40-75
40-76 WA1200-6
WA1200-6 40-77
40-78 WA1200-6
WA1200-6 40-79
40-80 WA1200-6
WA1200-6 40-81
40-82 WA1200-6
WA1200-6 40-83
Connector list and layout
Connector list and layout 40-84

Number
Connector No. Connector type Location Address
of pins
A01 Relay 4 Blower relay(Main) AO-9
A02 Relay 4 Blower relay(HI) AP-9
A03 Relay 4 Blower relay(M2) AP-9
A04 Relay 4 Cond relay AP-9
A05 Relay 4 Blower relay(M1) AO-9
A06 Relay 4 MAG.C.relay AO-9
A07 Relay 4 Cond HI(1)relay AO-9
A08 Relay 4 Cond HI(2)relay AP-9
A09 X 2 REC & FRE air servomotor AE-9
A10 M 2 Thermistor AU-2
A11 SWP 6 Air mix servo motor AU-2
A12 M 6 Blower motor & resistor AT-1
A13 YAZAKI 2 Air conditioner blower relay(M1) AT-6
A14 X 2 Air condenser Hi/Lo switch AS-6
A16 – 12 Air conditioner control amp BE-8
A17 – 16 Air conditioner control amp BE-8
A18 SWP 8 Air conditioner left air flow servomotor BE-1
A19 SWP 8 Air conditioner right air flow servomotor BC-4
ACC Terminal 1 Starter switch ACC terminal Y-5
AL01 Terminal 1 Battery relay LH V-3
AL03 Terminal 1 Battery relay LH T-9
AR01 Terminal 1 Battery relay RH P-8
AR02 Terminal 1 Battery relay RH P-8
AR03 Terminal 1 Battery relay RH R-9
AR04 Terminal 1 Battery relay RH Q-9
ASS SWP 2 Air suspention seat AR-7
B06 DT2 2 Dust indicator 1 H-9
B07 DT2 2 Dust indicator 2 G-9
B Terminal 1 Starter switch B terminal Y-4
BR Terminal 1 Starter switch BR terminal Y-4
BR1 DT2 6 Intermediate connector I-2
C Terminal 1 Starter switch C terminal Y-4
C1 HD36-24 23 Engine controller S-9
C2 HD36-24 31 Engine controller T-9
C01 M 6 Front wiper motor BC-3
C02 08027 4 Left wiper motor BG-2
C03 08027 4 Right wiper motor BC-5
C04 One-pin connector 1 Cigarette lighter Y-7
C05 08032 1 Cigarette lighter AA-9
C05 Terminal 1 GND –
C06 M 2 Air conditioner –
C07 One-pin connector 1 Intermediate connector –
C11 08027 6 Front wiper switch BD-8
C12 SWP 6 Rear wiper switch BH-5
C13 08027 4 Front wiper change switch BD-8
C14 SWP 6 Fog lamp switch(If equipped.) –
C15 YAZAKI PA 9 AM/FM radio –
C16 SWP 6 Stairway lamp switch BC-7
C17 SWP 6 Rear side work lamp switch BC-7
C18 SWP 6 Warning lamp (beacon) switch (If equipped.) BC-7
40-84 WA1200-6
Number
of pins
C19 08027 2 Speaker LH BH-7
C20 08027 2 Speaker RH BF-8
C21 Terminal 1 Door switch RH(room lamp) BD-8
C22 Terminal 1 Door switch LH(room lamp) BH-5
C23 08027 2 Room lamp BH-2
C24 Terminal 1 GND –
C25 DT2 2 Intermediate connector BF-8
C26 M 6 Rear wiper motor BH-4
C27 M 2 Front work lamp RH BC-6
C28 M 2 Front work lamp LH BG-2
C29 08027 2 Room lamp BE-9
C30 M 2 Stairway lamp RH BG-8
C31 DT2 2 Warning lamp (beacon) (If equipped.) BG-8
C32 DT2 2 Warning lamp (beacon) (If equipped.) BE-9
CAN1 DT2 3 Resistor –
CB1 DTHD4 1 Intermediate connector V-1
CB9 DTHD4 1 Intermediate connector U-2
CB1A Terminal 1 Circuit breaker M-9
CB4A Terminal 1 Circuit breaker N-9
CB1B Terminal 1 Circuit breaker M-9
CB4B Terminal 1 Circuit breaker N-9
CHK DT2 4 N MODE(STD) AO-1
CL1 DRC 40 Intermediate connector AB-1
WA1200-6 40-85
Number
of pins
CL2 DT2A 12 Intermediate connector AA-1
CL3 DT2 6 Intermediate connector AA-1
DIO – 2 Diode –
DL1 MS310A A4S-5S 5 FOR KOMATSU PC Y-5
E3 DT2 3 Engine controller S-9
E03 Terminal 1 Alternator L-6
E04 DT2 6 Intermediate connector L-5
E05 Terminal 1 Alternator J-3
E10 DT2 2 Compressor magnet switch L-7
E11 DT2 2 Diode –
E13 Terminal 1 Engine GND H-1
E14 DT2 3 Intermediate connector X-3
E16 08027 6 Regulator I-2
E18 Terminal 1 GND S-9
E20 Terminal 1 Starter relay W-2
E24 Terminal 1 Conventional starter H-1
E25 Terminal 1 Conventional starter H-1
E26 Terminal 1 Conventional starter W-6
E27 Terminal 1 Conventional starter I-2
E27 – 4 Enginr oil level sensor W-5
EM01 Terminal 1 Emergency engine stop switch AK-7
EM02 Terminal 1 Emergency engine stop switch AK-7
EM6 Terminal 1 Emergency engine stop rear RH G-9
EM7 Terminal 1 Emergency engine stop rear RH G-9
EM8 Terminal 1 Emergency engine stop rear LH K-3
EM9 Terminal 1 Emergency engine stop rear LH L-3
E28 DT2 2 Intermediate connector W-3
E29 DT2 2 Intermediate connector W-6
EM1 DT2A 12 Intermediate connector N-1
EM2 Terminal 1 Emergency engine stop(Front RH) R-1
EM3 Terminal 1 Emergency engine stop(Front RH) R-1
EM4 Terminal 1 Emergency engine stop(Front LH) M-1
EM5 Terminal 1 Emergency engine stop(Front LH) M-1
ER1 DT1 6 Intermediate connector W-1
ER3 DT2 3 Intermediate connector X-1
ER4 DTHD3 1 Intermediate connector X-3
ER11A DT2 2 Intermediate connector W-1
ER11B DT2 2 Intermediate connector W-1
ER12 DTHD3 1 Intermediate connector G-1
ER15 Terminal 1 Battery disconnect switch –
ETH1 One-pin connector 1 Ether inj. Solenoid J-2
ETH2 DT2 2 Diode –
ETH3 One-pin connector 1 Ether inj. Solenoid J-2
F01 DT1 6 Intermediate connector A-5
F02 DT1 6 Intermediate connector D-1
40-86 WA1200-6
Number
of pins
F04 DT2 3 Boom angle switsh A-6
F05 DT2 3 Bucket positioner max tilt A-3
F06 DT2 3 Boom bottom pressure sensor E-1
F07 – 2 Horn D-1
F09 – 2 Horn A-4
F11 DT2 2 Work lamp (OP) A-2
F12 DT2 2 Work lamp (OP) B-1
F13 DT2 3 A-4
F14 DT2 3 Boom head pressure sensor E-1
F15 DT2 3 Wheel speed sensor A-2
F20 Terminal 1 Chassis GND E-9
F21 – 2 Horn C-1
F23 – 2 Horn A-5
FC01 AMP070 20 Monitor panel controller –
FC09 SWP 6 Parking brake switch Y-4
FC10 SWP 6 Load meter mode switch Y-3
FC11 SWP 6 LCD/LED tuning switch Y-3
FC12 SWP 6 Service meter switsh Y-2
FC13 08027 4 Lighting mode switch Z-2
FC14 – 7 Hazard switch AA-1
FC15 X 3 Variable traction control AC-1
FC16 X 3 Vehicle speed AC-1
FC17A One-pin connector 1 Diode AP-1
FC17B One-pin connector 1 Diode AP-1
FC18 SWP 6 Brake pedal cancel switch RH Z-2
FC19 DT2 2 Idle/throttle validation switch AA-1
FC20 DT2 6 Idle/throttle validation switch Z-2
FC21 SWP 6 LCD/LED change switch Y-3
FC22 SWP 6 Active working switch AC-1
FCL1 – 70 Intermediate connector AC-1
FCL2 DT1,DT2B 8 Intermediate connector AB-1
FH1 DT2 2 Diode –
FH2 DT2 2 Diode –
FH3 DT2 2 Diode –
FH4 DT2 2 Diode –
FCL1 – 70 Intermediate connector –
FCL2 DT1,DT2B 8 Intermediate connector –
FL1 HD-26886,HD-26096 14 Intermediate connector AJ-6
FL2 HD-25886,HD-25096 14 Intermediate connector AJ-5
FR1 HD-86886,HD-86086 23 Intermediate connector AI-2
FR2 HD-46882,HD-46082 21 Intermediate connector AJ-4
FUSE1 Fuse box 30 Fuse box AR-9
FUSE2 Fuse box 30 Fuse box AR-9
FUSE3 Fuse box 30 Fuse box AC-9
G01 DT2A 8 Intermediate connector -
G01 DT2A 8 Intermediate connector L-7
G02 DT2 8 Intermediate connector -
G02 DT2 3 Back buzzer relay L-7
G03 DT2 2 Back buzzer RH L-6
G04 DT2 2 Back buzzer LH -
G04 DT2 3 Stairway lamp switch L-4
G14 Terminal 1 GND K-3
GND1A Terminal 1 GND AI-8
WA1200-6 40-87
Number
of pins
GND1B Terminal 1 GND AI-8
GND2 Terminal 1 GND AK-8
GR02 DT2 8 Intermediate connector –
GR1 DT1A 12 Intermediate connector L-5
GR2 DT2A 8 Intermediate connector L-6
GR03 DT2 6 Rear combination lamp (LH) J-9
GR03 DT2 6 Rear combination lamp (RH) I-9
GR03 DT2 6 Intermediate connector(OP) W-9,X-9
GR04 DT2 2 Rear back lamp (LH) J-9
GR04 DT2 2 Rear back lamp (RH) I-9
GR04 DT2 2 Back lamp (OP) W-8,W-9
GR05 DT2 2 Rear work lamp LH K-9
GR05 DT2 2 Rear work lamp RH H-9
GR05 DT2 2 Work lamp (OP) W-9,X-9
GR06 DT2 2 Rear HID lamp (LH) –
GR06 DT2 2 Rear HID lamp (RH) –
GR07 DT2 2 Rear work lamp LH J-9
GR07 DT2 2 Rear work lamp RH I-9
GR08 DT2 3 Turn signal lamp W-9,X-9
GR09 DT2 3 Stop & signal lamp W-9,X-9
GR10 DT2 3 Engine room lamp switch LH L-6
GR11 DT2 3 Engine room lamp switch RH H-9
GR12 DT2 2 Rear side work lamp LH H-9
GR13 DT2 2 Rear side work lamp RH L-7
GR14 DT2 2 Star way lamp L-8
GR15 DT2 2 Engine room lamp LH J-9
GR16 DT2 2 Engine room lamp RH H-9
GR17 DT2 2 Coolant level sensor J-9
GR6 DT1 6 Intermediate connector L-5
GRE1 DT2 4 Intermediate connector M-6
HR1 DT2 2 NC(Neutral)solenoid V-9
HR2 DT2 2 Diode –
HR6 DT2 2 Rear brake level T-2
HR10 DT2 2 Front brake level T-2
HR14 DT2 2 Parking brake solenoid S-1
HR15 DT2 3 Front brake oil pressure sensor X-4
HR16 DT2 3 Rear brake oil pressure sensor X-5
HR17 DT2 2 Emergency brake switch X-5
HR18 DT2 2 Emergency brake switch X-4
HR19 DT2 2 Emergency parking brake release solenoid R-1
HR20 DT2 3 Front brake pressure switch R-1
HR21 DT2 3 Rear brake pressure switch X-4
HR22 DT2 2 BBC CUT OFF SOLENOID M-6
HR23 DT2 2 BOOM RAISE EPC1 O-9
HR24 DT2 2 BOOM LOWER EPC1 O-9
HR25 DT2 2 BUCKET TILT EPC1 O-9
HR26 DT2 2 BUCKET DUMP EPC1 O-9
HR27 DT2 2 BOOM RAISE EPC2 O-9
HR28 DT2 2 BOOM LOWER EPC2 O-9
HR29 DT2 2 BUCKET TILT EPC2 O-8
HR30 DT2 2 BUCKET DUMP EPC2 O-9
HR31 DT2 2 SW PUMP PNC SOLENOID1 O-7
HR32 DT2 2 SW PUMP PNC SOLENOID2 N-7
HR33 DT2 2 ACTIVE POWER UP SOLENOID S-1
HS1 DT2 2 Hydraulic oil temperature sensor M-4
HS2 DT2 3 Hydraulic oil pressure sensor M-5
HS3 DT2 3 Steering oil pressure sensor M-5
40-88 WA1200-6
Number
of pins
HS4 DT2 3 PPC oil pressure sensor U-9
HS5 DT2 2 Hydraulic oil level sensor M-5
HS6 DT2 2 Brake oil temperature sensor M-3
JB1 DT2B 8 Joint connector –
JB2 DT2 6 Joint connector –
JC1 DT2 6 Joint connector AQ-9
JC2 DT2 6 Joint connector AQ-9
JC3 DT2 6 Joint connector AN-9
JC4 DT2 6 Joint connector AP-1
JC5 DT2 6 Joint connector AO-1
JC6 DT2 6 Joint connector AD-9
JC7 DT2 6 Joint connector AD-9
JE2 DT1 6 Joint connector –
JE3 DT2B 8 Joint connector –
JF1 DT1 6 Joint connector –
JF4 DT2B 8 Joint connector –
JF5 DT1B 8 Joint connector –
JG1 DT1B 8 Joint connector K-8
JG2 DT2 6 Joint connector L-8
JG3 DT2 6 Joint connector L-8
JG4 DT1B 8 Joint connector –
JG4 DT1 6 Joint connector –
JGN DT2 6 Joint connector –
JGN DT2 6 Joint connector –
JGR2 DT1B 8 Joint connector P-9
JGR3 DT1B 8 Joint connector P-9
JHD DT2 6 Joint connector –
JHD DT2 6 Joint connector –
JL1 DT2 6 Joint connector –
JL2 DT2 6 Joint connector –
JL8 DT2 6 Joint connector AT-6
JL9 DT2 6 Joint connector AR-8,AT-6
JL10 DT2B 8 Joint connector AC-9
JL11 DT1B 8 Joint connector AU-6
JL12 DT1B 8 Joint connector AT-6
JM4 DT2 6 Joint connector –
JR1 DT1 6 Joint connector –
JR8 DT1B 8 Joint connector –
WA1200-6 40-89
Number
of pins
JRA DT2 6 Joint connector –
JRB DT2 6 Joint connector –
JT1 DT2B 8 Joint connector –
L02 DRC KEYA 24 Transmission controller AL-9
L03 DRC KEYA 40 Transmission controller AL-8
L04 DRC KEYB 40 Transmission controller AK-7
L05 DRC KEYA 24 Boom bucket & AJSS controller AL-8
L06 DRC KEYA 40 Boom bucket & AJSS controller AM-9
L07 DRC KEYB 40 Boom bucket & AJSS controller AN-9
L12 DT2 2 Transmission cut off pressure sensor AC-1
L16 DT2 2 Fog lamp AH-1
L17 M 2 If equipped power AD-9
L42 M 2 Caution buzzer 1 AV-6
L43 M 2 Caution buzzer 2 AO-1
L44 08027 6 Wiper relay AN-1
L45 Relay 5 Rear wiper AS-6
L46 08027 4 Flasher unit relay AN-1
L48 Relay 6 Fog lamp relay AS-7
L49 Relay 6 Stairway lamp relay AU-9
L51 Relay 6 Side work lamp relay AS-8
L52 Relay 5 Hazerd relay AS-7
L53 Relay 5 Stop lamp relay AS-9
L54 Relay 5 Back up alarm AT-9
L55 Relay 6 Horn relay AT-9
L56 Relay 6 Head light relay AT-9
L57 Relay 5 Neutral relay AS-8
L58 Relay 5 Turn L relay AS-8
L59 Relay 5 Parking brake safety relay AT-9
L60 Relay 6 Front work lamp relay AT-9
L61 Relay 6 Rear work lamp relay AT-9
L65 Relay 5 Turn R relay AS-6
L69 Relay 6 SW pump relay AS-9
L71 Relay 11 Power window relay AV-7
L75 Relay 6 Front axle work lamp relay AU-9
L81 DT2 2 Stop lamp switch AB-1
L89 SUMITOMO 16 Emergency parking brake release switch AG-9
L101 Relay 5 Small lamp relay AV-6
L104 Relay 6 Turn & hazerd relay AU-9
L106 Relay 5 Beacon relay AU-6
L117 Relay 6 Side wiper change over relay AU-9
L118 Relay 5 Front washer relay AS-8
L119 Relay 5 Side washer relay AU-9
L120 Relay 5 Wiper Lo relay AU-9
L121 Relay 5 Wiper Hi relay AV-9
L122 Relay 5 Wiper INT"LH"relay AV-8
L123 Relay 5 Wiper INT"RH"relay AV-8
L124 DT2 2 Diode AS-7
40-90 WA1200-6
Number
of pins
L127 Relay 5 Steering neutral relay AV-9
L132 Relay 5 Dust ingicator 1 relay AV-9
L141 DT2 3 Tilt sensor pitching AO-1
L142 DT2 3 Tilt sensor rolling –
L143 Relay 5 Buzzer 2 relay AV-8
L145 M 4 Dcconverter(24 V/12 V) AL-2
L151 YAZAKI 7123-8322 2 12 VDC socket Y-5
L160 Relay 8 Loader pump relay AV-8
LR1 DT1B 12 Intermediate connector AH-1
LR2 DTHD4 1 Intermediate connector AH-1
LR3 DTHD4 1 Intermediate connector AG-1
LR4 DTHD4 1 Intermediate connector AG-1
LR5 DTHD4 1 Intermediate connector AF-1
LR6 DTHD4 1 Intermediate connector AF-1
LR7 DTHD4 1 Intermediate connector AE-1
LR8 DTHD4 1 Intermediate connector AJ-7
LR9 DTHD4 1 Intermediate connector AJ-7
LR10 – 40 Intermediate connector AJ-5
LR11 – 70 Intermediate connector AJ-3
LR12 DT2C 12 Intermediate connector AJ-2
LS1 S(L) 12 Intermediate connector AK-8
LS3 S(W) 12 Intermediate connector AK-6
LS6 DTM 12 Intermediate connector AD-1
LS7 DT2,DTM 2 Intermediate connector AD-1
M6 AMP070 18 Multi monitor AN-1
M7 AMP070 12 Multi monitor AN-1
MC1 M 2 Resistor AV-7
MC2 DT2 2 Diode –
MC3 DT2 2 Diode –
MC4 M 2 Resistor AP-1
MC5 DT2 2 Diode AS-6
MC6 DT2 2 Diode AR-1
MC7 DT2 2 Diode AS-1
MMS DT2C 12 MMS master link AE-9
MT1 DT2 3 Transmission lubrication oil pressure sensor AZ-3
MT2 DT2 3 Transmission main oil pressure sensor AY-8
MT3 DT2 3 Transmission outlet oil pressure sensor AX-7
MT4 DT2 3 Transmission lubrication oil pressure sensor AZ-8
MT5 DT2 3 Transmission lubrication oil pressure sensor BB-5
ORB1 DRC KEYB 40 ORBCOM controller AC-1
ORB3 – 1 BNCP controller –
P1 HD36-24 16 Engne controller T-9
PH1 DT2 2 Ambient air temperature sensor O-9
PRE DT2 2 Pressure switch Q-9
PWR1 One-pin connector 1 power window regulator RH BC-4
PWR1 One-pin connector 1 power window regulator LH BF-1
PWR2 One-pin connector 1 power window regulator RH BC-4
PWR2 One-pin connector 1 power window regulator LH BF-1
R01 DT2 2 Transmission oil filter sensor S-1
R02 DT2 2 Transmission oil filter sensor R-1
R03 DT2 2 Diode -
R04 DT2 2 Diode -
R05 DT2 2 Fuel level sensor J-3
WA1200-6 40-91
Number
of pins
R06 DT2 2 Diode -
R07 DT2 2 Diode -
R11 DT2 2 Emergency steering ingicate switch M-3
R12 DT2 2 Emergency steering ingicate switch M-1
R20 Terminal 1 GND I-2
R22 08027 2 Front window sealed washer X-7
R23 DT2 2 Diode -
R24 8027 2 Rear window sealed washer X-7
R25 DT2 2 Diode -
R26 08027 2 Side window sealed washer X-7
R27 DT2 2 Diode -
R30 DT2 3 Condenser LH N-7
R31 DT2 3 Condenser RH O-7
R32 DT2 3 Frame angle sensor(Potentiometer) M-4
R33 DT2 2 J/S EPC solenoid M-4
RA1 DT2 6 Intermediate connector U-2
RA2 DT2 6 Intermediate connector O-7
RA3 DT2B 8 Intermediate connector T-2
RA4 DTHD4 1 Intermediate connector T-9
RA5 DT1 6 Intermediate connector U-2
RA7 DT2 2 Battery level sensor U-3
RA8 DT2 2 Battery level sensor P-8
RA9 DT2 2 Battery level sensor O-7
RA10 DT2 2 KOMTRAX Plus working lamp V-9
RA11 Terminal 1 Battery disconnect switch V-8
RA11 DT2 2 KOMTRAX Plus working lamp R-9
RE1 Relay 5 Auto grease relay Q-9
RE2 Relay 5 Auto grease relay Q-9
RES1 DT2 3 Resistor AL-2
RF90 DT2 2 For Grease level gauge(If equipped) N-1
RT1 HD-86086 23 Intermediate connector M-3,AW-6
RT2 HD-85086 23 Intermediate connector M-2,AW-6
S01 DT2 2 Boom N lock switch AL-9
S02 DT2 4 Boom & bucket EPC lever AN-9
S03 DT2 4 Boom & bucket EPC lever AL-9
S04 DT2 2 Boom & bucket EPC lever Y-6
S05 DT2 2 Boom & bucket EPC lever Y-6
S06 DT2 2 Boom & bucket EPC lever AM-9
S07 DT2 4 Boom lever KDS & speed limit ON/OFF switch AM-9
S08 DT2 4 Bucket lever for load meter Y-6
S09 SWP 6 Auto digging switch AA-9
S010 – 7 Power window LH Y-8
S011 – 7 Power window RH Z-8
S012 SWP 6 Boom remote positioner set switch AA-9
S014 SWP 6 Auto grease switch AB-9
S015 SWP 6 Intermediate connector AN-9
S018 SWP 6 PRM lock switch AB-9
S019 SWP 6 Resume / deccel switch AA-9
S020 SWP 6 Auto manual switch Z-9
S021 SWP 6 Cut off set switch Y-8
S022 SWP 6 Turn signal switch –
S023 SWP 6 Transmission cut off switch Y-7
S024 DT2 4 Work lamp switch Y-7
S30 DT2 3 AJSS lever angle sensor AI-8
S31 DTM 12 Joy stick lever switch AH-8
SC1 DT2A 12 Service connector AG-9
SC2 DT2A 12 Service connector AF-9
SC3 HD10-9-1939PE 10 Service connector AR-7
STL DT2 2 S/T lock switch AD-1
40-92 WA1200-6
Number
of pins
SV1 – 4 Solenoid 1 P-9
SW1 One-pin connector 1 Pressure switch Q-9
SW2 One-pin connector 1 Pressure switch Q-9
T1 Terminal 1 GND –
T3 DT2 2 1st ECMV solenoid AX-9
T4 DT1 2 1st fill switch AX-9
T5 DT2 2 2nd ECMV solenoid AW-9
T6 DT1 2 2nd fill switch AW-9
T7 DT2 2 3rd ECMV solenoid AW-9
T8 DT1 2 3rd fill switch AW-9
T9 DT2 2 Modulation clutch solenoid BB-5
T10 DT1 2 Modulation clutch fill switch BB-7
T11 DT2 2 R ECMV solenoid BB-2
T12 DT1 2 R fill switch BB-2
T13 DT2 2 F ECMV solenoid BA-2
T14 DT1 2 F fill switch BB-2
T15 DT2 2 Speed sensor AW-5
T16 DT2 2 Modulation clutch speed sensor BB-7
T17 DT2 2 Engine speed sensor AY-8
T18 DT2 2 Parking brake indicate switch AZ-2
T19 DT2 2 Transmission oil temperature sensor BB-4
T20 DT2 2 1st bypass solenoid AX-9
T21 DT2 2 R bypass solenoid BA-2
T22 DT2 2 F bypass solenoid BA-2
T23 DT2 2 R drain solenoid BA-2
T24 DT2 2 Torque converter oil temperature sensor F-9, BA-9
T25 DT2 2 Transmission oil temperature 2 sensor F-9, BB-4
TIM – 10 Timer Q-9
TURN DT2 3 Front combination lamp RH B-7
TURN DT2 3 Front combination lamp LH D-8
V1 AMP070 20 KOMTRAX Plus controller AK-6
V2A AMP070 18 KOMTRAX Plus controller AK-5
V2B AMP070 12 KOMTRAX Plus controller AK-4
V15 One-pin connector 1 Diode(Green) O-1
V16 One-pin connector 1 Diode(Green) O-1
V17 Terminal 1 Wake up switch O-1
VDL BENDIX 5 KOMTRAX Plus download box Q-1
WORK1 DT2 2 Head lamp RH B-7
WORK1 DT2 2 Head lamp LH F-1
WORK2 DT2 2 Head lamp RH C-8
WORK2 DT2 2 Head lamp LH D-8
WORK3 DT2 2 Head lamp RH C-7
WORK3 DT2 2 Head lamp LH F-1
WA1200-6 40-93
40-94 WA1200-6
WA1200-6 40-95
40-96 WA1200-6
WA1200-6 40-97
40-98 WA1200-6
WA1200-6 40-99
40-100 WA1200-6
WA1200-6 40-101
40-102 WA1200-6
WA1200-6 40-103
T- branch box and T- branch adapter table
T- branch box and T- branch adapter table 40-104

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
Part No. Part name cati-on
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO 2P q q
ECONO
799-601-2790 Adapter for ECONO 12
12P
q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
ECONO
799-601-2840 Extension cable (ECONO type) 12
12P
q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799 -601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 - q q
799 -601-7090 Adapter for M 2 M2P q q q q
799-601-7110 Adapter for M 3 M3P q q q q
799-601-7340 Adapter for M 8 M8P q
40-104 WA1200-6
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
symbol
799-601-7140 Adapter for M 8 S8P q q q q

799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 – q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 – q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601- 9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine(CRI-T3) PCV
2 P q q
WA1200-6 40-105
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identifi-
symbol
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q

795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 – q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140
Ambient pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Common rail pressure
3 1, 2, 3 L q q
799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4 C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3 A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3 B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)
799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799 -601-4260 Adapter for controller (ENG) 4 DTP4 q q
799 -601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 – q
799-601-4280* Box for controller (PUMP) 121 – q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 to 4 and DTM2 3, – q
4
“*” Shows not T-adapter but socket.
40-106 WA1200-6
Table of fuse locations
Table of fuse locations 40-107

Connection table of circuit breaker 40-107
q This connection table shows the devices to which each power supply of the circuit breakers supplies pow-
er.
q When performing troubleshooting related to the electrical system, check the circuit breakers first to see if
the power is supplied properly.
a If the circuit breaker works, the button pops out.If this happens, press in the button and check if the button
pops out again when the starting switch is turned to the "ON" position, engine started, and the machine
operated.If the button pops out again, there may be a ground fault.
a The switched power supply is the power (battery relay output) which is supplied while starting switch is in
the ON position. By contrast, the continuous power supply is the power (battery direct output) which is sup-
plied regardless of the starting switch position, ON or OFF.
Circuit
Circuit breaker
Type of power supply breaker Destination of power
No.
capacity
1 60 A Fuse box III 4 to 7
Front working lamp (1)
2 60 A
Fuse box III 1 to 3
3 60 A Fuse box II 10 to 14
Switched power supply
(battery relay M terminal) Horn
4 60 A
Fuse box II 1 to 9
Work equipment pump solenoid
5 60 A
Fuse box I 13 to 15
6 60 A Fuse box I 10 to 12
Continuous power supply 7 50 A Fuse box I 6 to 9
(battery relay B terminal) 8 50 A Fuse box I 1 to 5
Switched power supply 9 135 A Alternator power supply
(battery relay M terminal) 10 135 A Alternator power supply
11 20 A Engine controller
Continuous power supply 12 20 A Engine controller
(battery relay B terminal) 13 20 A Engine controller
WA1200-6 40-107
Connection table of fuse 40-108

q This connection table shows the devices to which fuses in the fuse box supplies power.
a The switched power supply is the power (battery relay output) which is supplied while starting switch
is in the ON position. By contrast, the continuous power supply is the power (battery direct output)
which is supplied regardless of the starting switch position, ON or OFF.
q When performing out troubleshooting related to the electric system, check the fuse box to see if the power
is supplied properly.
Fuse box I
Type of power supply Fuse No. Fuse capacity Destination of power
1 20 A Starting switch
2 10 A CAN power supply line
Continuous power supply
3 5A Transmission controller (B)
(circuit breaker No. 8)
4 5A Work equipment controller (B)
5 10 A KOMTRAX Plus main monitor
6 10 A Hazard lamp
Continuous power supply 7 10 A Spare (continuous power supply)
(circuit breaker No. 7) 8 20 A Step lamp
9 10 A Spare
10 20 A Air conditioner (A)
11 20 A Air conditioner (B)
12 20 A Air suspension seat, cigarette lighter
13 10 A Work equipment pump solenoid
14 30 A Spare
15 20 A Revolving warning lamp (if equipped)
Fuse box II
1 20 A Horn
2 10 A Turn signal lamp
3 20 A Buckup lamp and brake lamp
4 10 A Transmission controller (A)
5 5A Parking brake pilot lamp
6 5A Emergency parking brake
7 10 A Work equipment controller (A)
8 10 A KOMTRAX Plus controller
9 10 A Radio
10 10 A Auto-greasing pilot lamp
11 20 A Front wiper and washer
Switched power supply 12 20 A Rear wiper and washer
(circuit breaker No. 3) 13 20 A Power window L.H.
14 20 A Power window R.H.
15 – –
40-108 WA1200-6
Fuse box III

1 20 A Front working lamp (1)
2 20 A Rear working lamp
4 30 A Fog lamp, side working lamp
5 20 A Main lamp circuit
6 10 A Spare
Switched power supply 7 10 A Spare
(circuit breaker No. 1) 8 10 A Right clearance lamp
9 10 A Left clearance lamp
10 10 A Right headlamp
11 10 A Left headlamp
12 5A Engine controller
(circuit breaker No. 11 to 14)
Auto greasing system level gauge
13 5A
Switched power supply (if equipped)
(circuit breaker No. 7) 14 – –
15 – –
Location of fuse box and fuse number

Fuse box I, II Fuse No. I, II
Fuse box III Fuse No. III
WA1200-6 40-109
(01)
Table of fuse locations (Pictorial SPEC.)

Connection table of circuit breaker 40-107
q This connection table shows the devices to which each power supply of the circuit breakers supplies pow-
er.
q When performing troubleshooting related to the electrical system, check the circuit breakers first to see if
the power is supplied properly.
a If the circuit breaker works, the button pops out.If this happens, press in the button and check if the button
pops out again when the starting switch is turned to the "ON" position, engine started, and the machine
operated.If the button pops out again, there may be a ground fault.
a The switched power supply is the power (battery relay output) which is supplied while starting switch is in
the ON position. By contrast, the continuous power supply is the power (battery direct output) which is sup-
plied regardless of the starting switch position, ON or OFF.
Circuit
Circuit breaker
Type of power supply breaker Destination of power
No.
capacity
1 60 A Fuse box III 4 to 7
Front working lamp (1)
2 60 A
Fuse box III 1 to 3
3 60 A Fuse box II 10 to 14
(battery relay M terminal) Horn
4 60 A
Fuse box II 1 to 9
Work equipment pump solenoid
5 60 A
Fuse box I 13 to 15
6 60 A Fuse box I 10 to 12
Continuous power supply 7 50 A Fuse box I 6 to 9
(battery relay B terminal) 8 50 A Fuse box I 1 to 5
Switched power supply 9 135 A Alternator power supply
(battery relay M terminal) 10 135 A Alternator power supply
Continuous power supply 12 20 A Engine controller
(battery relay B terminal) 13 20 A Engine controller
40-109-1 WA1200-6
(01)
Connection table of fuse 40-108

q This connection table shows the devices to which fuses in the fuse box supplies power.
a The switched power supply is the power (battery relay output) which is supplied while starting switch
is in the ON position. By contrast, the continuous power supply is the power (battery direct output)
which is supplied regardless of the starting switch position, ON or OFF.
q When performing out troubleshooting related to the electric system, check the fuse box to see if the power
is supplied properly.
Fuse box I
1 20 A Starting switch
Continuous power supply 2 10 A CAN power supply line
3 5A Transmission controller (B)
(circuit breaker No. 8) 4 5A Work equipment controller (B)
5 10 A KOMTRAX Plus main monitor
6 10 A Hazard lamp
Continuous power supply 7 10 A Spare (continuous power supply)
(circuit breaker No. 7) 8 20 A Step lamp
9 10 A Spare
Continuous power supply 10 20 A Air conditioner (A)
11 20 A Air conditioner (B)
(circuit breaker No. 6) 12 20 A Air suspension seat, cigarette lighter
Continuous power supply 13 10 A Work equipment pump solenoid
14 30 A Spare
(circuit breaker No. 5) 15 20 A Revolving warning lamp (if equipped)
Fuse box II
16 20 A Horn
17 10 A Turn signal lamp
18 20 A Buckup lamp and brake lamp
Switched power supply 19 10 A Transmission controller (A)
20 5A Parking brake pilot lamp
(circuit breaker No. 5) 21 5A Emergency parking brake
22 10 A Work equipment controller (A)
23 10 A KOMTRAX Plus controller
24 10 A Radio
25 10 A Auto-greasing pilot lamp
26 20 A Front wiper and washer
Switched power supply 27 20 A Rear wiper and washer
(circuit breaker No. 3) 28 20 A Power window L.H.
29 20 A Power window R.H.
30 – –
Fuse box III

32 20 A Rear working lamp
34 30 A Fog lamp, side working lamp
35 20 A Main lamp circuit
36 10 A Spare
Switched power supply 37 10 A Spare
(circuit breaker No. 1) 38 10 A Right clearance lamp
39 10 A Left clearance lamp
40 10 A Right headlamp
41 10 A Left headlamp
42 5A Engine controller
(circuit breaker No. 11 to 14)
43 5A Auto greasing system level gauge (if equipped)
44 – –
45 – –
WA1200-6 40-109-2
(01)
Location of fuse box and fuse number

Fuse box I, II Fuse No. I
Fuse No. II
Fuse box III Fuse No. III
40-109-3 WA1200-6
(01)
FOR AJSS SPECIFICATION MACHINE

Location and connection table for relay
Relay Relay
Relay name Remarks Relay name Remarks
No. No.
L118 Front windshield washer L56 Head light
L51 Side working light L119 Side windshield washer
L69 SW pump pnc sol L71 Power window
L57 Neutral L49 Stairway light
L58 Turn (L) L117 Wiper changeover
L59 P/B safety L75 Working light
L60 Front working light L120 Wiper relay low
L61 Rear working light L134 Dust indicator
L52 Hazzard L127 S/T neutral inter lock
L53 Stop light L121 Wiper relay high
L54 Backup alarm L135 Dust indicator
L55 Horn L123 Wiper interval RH
L104 Turn signal light・hazzard L132 Dust indicator
L48 Fog lamp L143 Buzzer 2
L45 Rear wiper L122 Wiper interval LH
L65 Turn (R) L133 Dust indicator
L106 (Beacon lamp) L160 Working system
L101 Side marker light
WA1200-6 40-109-4
(01)
Location and connection table for air conditioner relay

Relay
Relay name Remarks
No.
A05 Blower
A01 Blower
A06 Magnetic clutch
A02 Blower
A07 Condenser LH
A03 Blower
A08 Condeser RH
A04 Condenser
40-109-5 WA1200-6
(01)
WA1200-6 40-109-6
(01)
Troubleshooting by failure code
Failure code [1500L0] Double Engagement of Transmission Clutches
Troubleshooting by failure code 40-1 0

Failure code [1500L0] Double Engagement of Transmission Clutches 40-1 0
WA1200-6
Action
Failure code Detection of double engagements
level Failure
(Transmission controller system)
E03 1500L0
Detail of failure q A fill signal is input for a combination of double engagements.
q Turns centralized warning lamp and alarm buzzer ON.
Action of con-
q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller
to OFF position.
Problem on
q Transmission may be damaged.
machine
Related infor-
q Method of reproducing failure code: Turn starting switch to ON position.
mation
No. Cause Procedure, measuring location, criteria and remarks

1 See failure codes "15SAL1", "15SBL1", "15SEL1", "15SFL1", and "15SGL1".
40-110 WA1200-6
Failure code [1540N1] T/M overrun
Failure code [1540N1] T/M overrun 40-1 1

Action
Failure code T/M overrun alarm
level Failure
(Transmission controller)
E02 1540N1
q When gear speed is in other than neutral, a transmission output shaft speed signal exceeding the
Detail of failure
limit specified to each gear speed for overrun prevention is detected.
Action of con- q Turns the centralized warning lamp and alarm buzzer ON.
troller q Returns to normal condition when transmission output shaft speed becomes below 1418 rpm.
Problem on
q Continuing to travel in this condition may lead to transmission damage.
machine
Related infor- q Information on transmission overrunning prevention command activation is obtained from trans-
mation mission controller over the network.

q Engine is overrunning if machine is traveling as indicated by the transmis-
1 Engine overrun
sion output shaft speed signal exceeding 1,527 rpm
q If machine is not traveling as indicated by the transmission output shaft
2 Defective transmission controller
speed signal exceeding 1,527 rpm, transmission controller is defective
WA1200-6 40-111
Failure code [15B0NX] T/M Oil Filter Clogged
Failure code [15B0NX] T/M Oil Filter Clogged 40-1 2

Action
Failure code Clogging of transmission oil filter
level Failure
(Monitor panel controller system)
E01 15B0NX
Detail of failure Transmission oil filter clogging is indicated
Action of con- q Even if cause of failure disappears, machine does not become normal until starting switch is turned
troller to OFF position.
Problem on
Clogging warning output (false detection)
machine
a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshoot-
Related infor- ing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the
mation monitor
q This failure code is issued when the engine is running

1. Prepare with starting switch at OFF position.
Clogged transmission oil filter, or 2. Disconnect connector R01 and connect T-adapter.
1 defective transmission oil filter 3. Turn the starting switch to OFF position, then perform troubleshooting.
sensor (R01) Check if indication goes out when a jumper wire is connected between trans-
mission oil filter sensor (R01) (female) (1) and (2)
Clogged transmission oil filter, or 2. Disconnect connector R02 and connect T-adapter.
2 defective transmission oil filter 3. Turn the starting switch to OFF position, then perform troubleshooting.
sensor (R02) Check if indication goes out when a jumper wire is connected between trans-
mission oil filter sensor (R02) (female) (1) and (2)
2. Connect T-adapter to FC04 connector and each connector to be discon-
nected in turn.
3. Turn the starting switch to OFF position, then perform troubleshooting.
Wiring harness between FC04 (female) (5) and R01
Open circuit in wiring harness Max. 1 z
(female) (1)
3 (wire breakage or defective con-
tact of connector) Max. 1 z
(female) (1)
Resistance
Wiring harness between R01 (female) (2) and
Max. 1 z
ground
Wiring harness between R02 (female) (2) and
Max. 1 z
ground
2. Disconnect connector JR6 and connect T-adapter.
4 Defective joint connector (JR6) 3. Turn the starting switch to OFF position, then perform troubleshooting.
Wiring harness between JR6 (male) (6), (8) and (1) Resistance Max. 1 z
2. Disconnect FC03 or FC04 and connect T-adapter.
3. Turn starting switch to ON position and perform troubleshooting.
5 Defective monitor panel controller FC03 Oil filter Voltage
Normal Max 1 V
Between (5) and ground
Clogged 17 – 30 V
40-112 WA1200-6
Failure code [15B0NX] T/M Oil Filter Clogged
Related circuit diagram 40-1 3
WA1200-6 40-113
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit 40-1 4
Action
Failure code Ground fault in E-POC fill switch F
level Failure
E03 15SAL1
q When the signal is not output to F (forward) ECMV solenoid, the signal is output from F (forward)
Detail of failure
ECMV fill switch, and the clutch is not released.
q Judges that the signal is output from F (forward) ECMV fill switch.
troller q Even if cause of failure disappears, machine does not become normal until directional lever or di-
rectional selector switch is set to N (NEUTRAL).
Problem on
q F (forward) travel is enabled, but R (reverse) travel is disabled.
machine
q The output state (current) to the F (forward) clutch ECMV solenoid can be checked with the mon-
itoring function (Code: 31608, ECMV F DIR).
Related infor-
q The input state (ON/OFF) from the F (forward) fill switch can be checked with the monitoring func-
mation
tion (Code: 40908, D-IN-25).
q Method of reproducing failure code: Start engine

2. Disconnect connector T14 and connect T-adapter.
3. Start engine and perform troubleshooting.
q Parking brake switch: OFF
q Keep depressing the brake pedal to prevent the machine from traveling.
Defective F (forward) ECMV fill
1 Directional lever or
switch (Internal short circuit)
T14 (male) directional selector Resistance
switch
F (Forward) Max. 1 z
Other than above Min. 1 Mz
2. Connect T-adapter to L03 connector and each connector to be discon-
Ground fault in wiring harness nected in turn.
2 3. Turn the starting switch to OFF position, then perform troubleshooting.
(contact with ground circuit)
Between ground and wiring harness from L03
Resistance Min. 1 Mz
(female) (27) to T14 (female) (1)
3 Defective transmission controller Directional lever or
L03 directional selector Voltage
switch
F (Forward) Max. 1 V
Other than above 8–10 V
40-114 WA1200-6
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit
WA1200-6 40-115
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect 40-1 6
Action
Failure code Open circuit or hot short circuit in E-POC fill switch F
level Failure
E01 15SALH
q When the signal is not output to F (forward) ECMV solenoid, the signal is output from F (forward)
Detail of failure
q Judges that the signal is output from F (forward) ECMV fill switch.
troller q Even if cause of failure disappears, machine does not become normal until directional lever or di-
Problem on
q F (forward) travel is enabled, but R (reverse) travel is disabled.
machine
q The output state (current) to the F (forward) clutch ECMV solenoid can be checked with the mon-
itoring function (Code: 31608, ECMV F DIR).
Related infor-
q The input state (ON/OFF) from the F (forward) fill switch can be checked with the monitoring func-
mation
tion (Code: 40908, D-IN-25).

Defective F (forward) ECMV fill
switch (Internal open circuit)
T14 (male) directional selector
Resistance
switch
F (Forward) Max. 1 z
Hot short circuit in wiring harness nected in turn.
2 3. Turn starting switch to ON position and perform troubleshooting.
(contact with 24 V circuit)
Voltage Max. 1 V
L03 directional selector
Voltage
switch
F (Forward) Max. 1 V
40-116 WA1200-6
Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect
WA1200-6 40-117
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit 40-1 8
Action
Failure code Ground fault in E-POC fill switch R
level Failure
E03 15SBL1
q When the signal is not output to R (reverse) ECMV solenoid, the signal is output from R (reverse)
Detail of failure
q Judges that the R (reverse) ECMV fill switch signal is ON.
troller q Even if cause of failure disappears, machine does not become normal until directional selector
switch is set to N (NEUTRAL).
Problem on
q The machine can travel in reverse, but cannot travel forward.
machine
q Output condition (current) to R (reverse) clutch ECMV solenoid can be checked with monitoring
function (Code: 31606, ECMV R DIR).
Related infor-
q Input condition (ON/OFF) from the R (reverse) fill switch can be checked with monitoring function
mation
(Code: 40908 D-IN-26).

Defective R (reverse) ECMV fill
switch (internal short circuit)
T12 (made) directional selector Resistance
switch
R (forward) Max. 1 z
switch
R (forward) Max. 1 V
40-118 WA1200-6
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit
WA1200-6 40-119
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect 40-120
Action
Failure code Open circuit or hot short circuit in E-POC fill switch R
level Failure
E01 15SBLH
q When the signal is not output to R (reverse) ECMV solenoid, the signal is output from R (reverse)
Detail of failure
q Judges that the R (reverse) ECMV fill switch signal is ON.
troller q Even if cause of failure disappears, machine does not become normal until directional selector
Problem on
q The machine can travel in reverse, but cannot travel forward.
machine
q Output condition (current) to R (reverse) clutch ECMV solenoid can be checked with monitoring
function (Code: 31606, ECMV R DIR).
Related infor-
q Input condition (ON/OFF) from the R (reverse) fill switch can be checked with monitoring function
mation
(Code: 40908 D-IN-26).

Defective R (reverse) ECMV fill
T12 (made) directional selector Resistance
switch
R (forward) Max. 1 z
Voltage Max. 1 V
switch
R (forward) Max. 1 V
40-120 WA1200-6
Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect
WA1200-6 40-121
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit 40-12
Action
Failure code Ground fault in E-POC fill switch 1
level Failure
E03 15SEL1
q When 1st ECMV solenoid output is de-energized, 1st ECMV fill switch signal ON is input, and
Detail of failure
clutch is not released.
q Judges that the 1st ECMV fill switch signal is ON.
q Holds 2nd and 3rd proportional solenoid outputs OFF.
Action of con-
q Turns the centralized warning lamp and alarm buzzer ON.
troller
q Even if cause of failure disappears, machine does not become normal until directional lever or di-
Problem on
q The machine can travel in 1st, but not in 2nd or 3rd.
machine
q The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring
function (Code: 31602, ECMV 1 DIR).
Related infor-
q The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function
mation
(Code: 40908, D-IN-27).

Defective 1st ECMV fill switch q Keep depressing the brake pedal to prevent the machine from traveling.
1
(internal short circuit)
T4 (male) Gearshift lever Resistance
1st Max. 1 z
2
(contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting.
2. Disconnect connector L03 and connect T-adapter.
3 Defective transmission controller q Set the auto shift and manual shift selector switch to MANUAL.
q Set the directional lever to F or R position.
L03 Gearshift lever Voltage
1st Max. 1 V
40-122 WA1200-6
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit
WA1200-6 40-123
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect 40-124
Action
Failure code Open circuit or hot short circuit in E-POC fill switch 1
level Failure
E01 15SELH
q When 1st ECMV solenoid output is de-energized, 1st ECMV fill switch signal ON is input, and
Detail of failure
q Judges that the 1st ECMV fill switch signal is ON.
q Holds 2nd and 3rd proportional solenoid outputs OFF.
Action of con-
troller
Problem on
q The machine can travel in 1st, but not in 2nd or 3rd.
machine
q The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring
Related infor-
q The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function
mation
(Code: 40908, D-IN-27).

Defective 1st ECMV fill switch q Keep depressing the brake pedal to prevent the machine from traveling.
1
(Internal open circuit)
1st Max. 1 z
2
(contact with 24 V circuit) 3. Turn starting switch to ON position and perform troubleshooting.
Voltage Max. 1 V
q Set the auto shift and manual shift selector switch to MANUAL.
Gearshift lever
L03 Voltage
1st Max. 1 V
40-124 WA1200-6
Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect
WA1200-6 40-125
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit 40-126
Action
level Failure
E03 15SFL1
q When 2nd ECMV solenoid output is de-energized, 2nd ECMV fill switch signal ON is input, and
Detail of failure
q Judges that the 2nd ECMV fill switch signal is ON.
Action of con-
q Holds 1st and 3rd proportional solenoid outputs OFF.
troller
Problem on
q The machine may be able to travel in 2nd, but not in 1st or 3rd.
machine
q The output (current value) to the 2nd clutch ECMV solenoid can be checked with the monitoring
Related infor-
q The input condition (ON/OFF) from the 2nd fill switch can be checked with the monitoring function
mation
(Code: 40908, D-IN-28).

1. Prepare with starting switch AT OFF position.
Defective 2nd ECMV fill switch q Keep depressing the brake pedal to prevent the machine from traveling.
1
2nd speed Max. 1 z
2 3. Turn the starting switch to off position, then perform troubleshooting.
1. Prepare with starting switch At OFF position.
2nd speed Max. 1 V
40-126 WA1200-6
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit
WA1200-6 40-127
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect 40-128
Action
level Failure
E01 15SFLH
q When 2nd ECMV solenoid output is de-energized, 2nd ECMV fill switch signal ON is input, and
Detail of failure
q Judges that the 2nd ECMV fill switch signal is ON.
Action of con-
q Holds 1st and 3rd proportional solenoid outputs OFF.
troller
Problem on
q The machine may be able to travel in 2nd, but not in 1st or 3rd.
machine
q The output (current value) to the 2nd clutch ECMV solenoid can be checked with the monitoring
Related infor-
q The input condition (ON/OFF) from the 2nd fill switch can be checked with the monitoring function
mation
(Code: 40908, D-IN-28).

Defective 2nd ECMV fill switch q Keep depressing the brake pedal to prevent the machine from traveling.
1
(internal disconnection)
2nd speed Max. 1 z
Voltage Max. 1 V
2nd speed Max. 1 V
40-128 WA1200-6
Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect
WA1200-6 40-129
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit 40-130
Action
level Failure
E03 15SGL1
q When 3rd ECMV solenoid output is de-energized, 3rd ECMV fill switch signal ON is input, and
Detail of failure
q Judges that the 3rd ECMV fill switch signal is ON.
q Holds 1st and 2nd proportional solenoid outputs OFF.
Action of con-
troller
q Even if cause of failure disappears, machine does not become normal until directional selector
Problem on
q The machine may be able to travel in 3rd, but not in 1st or 2nd.
machine
q The output (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring
Related infor-
q The input condition (ON/OFF) from the 3rd fill switch can be checked with the monitoring function
mation
(Code: 40908, D-IN-29).

Defective 3rd ECMV fill switch q Keep depressing the brake pedal to prevent the machine from traveling.
1
3rd Max. 1 z
2
(contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting.
3rd Max. 1 V
40-130 WA1200-6
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit
WA1200-6 40-131
Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect
Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect 40-132
Action
level Failure
E01 15SGLH
q When 3rd ECMV solenoid output is de-energized, 3rd ECMV fill switch signal ON is input, and
Detail of failure
q Judges that the 3rd ECMV fill switch signal is ON.
q Holds 1st and 2nd proportional solenoid outputs OFF.
Action of con-
troller
q Even if cause of failure disappears, machine does not become normal until directional selector
Problem on
q The machine may be able to travel in 3rd, but not in 1st or 2nd.
machine
q The output (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring
Related infor-
q The input condition (ON/OFF) from the 3rd fill switch can be checked with the monitoring function
mation
(Code: 40908, D-IN-29).

Defective 3rd ECMV fill switch q Keep depressing the brake pedal to prevent the machine from traveling.
1
(internal open circuit)
3rd Max. 1 z
2
(contact with 24 V circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting.
Voltage Max. 1 V
3rd Max. 1 V
40-132 WA1200-6
WA1200-6 40-133
40-134 WA1200-6
Failure code [2F00MA] Parking brake circuit failure
Failure code [2F00MA] Parking brake circuit failure 40-135

Action
Failure code Open circuit in parking brake signal line
level Failure
(Machine monitor system)
E03 2F00MA
q When the F or R clutch is engaged, there is open circuit in the parking brake operation sensor cir-
Detail of failure
cuit. (The neutralizer does not work.)
troller q If cause of failure disappears, machine becomes normal by itself.
Problem on
q Parking brake drags (kept operated)
machine
q Input condition (ON/OFF) from the parking indicator switch can be checked with monitoring function
Related infor- (Code: 40903 DIN-26).
mation q Engine may stall during travel or emergency brake activation may issue this error

Defective parking brake indicator 3. Turn the starting switch to OFF position, then perform troubleshooting.
1 switch T18 (male) Parking brake pilot lamp Resistance
Released Max. 1 z
Between (1) and (2)
Operation Min. 1 Mz
2. Disconnect connector FC09 and connect T-adapter.
Parking brake pilot lamp
FC09 (female) Resistance
Switch
Defective parking brake indicator ON Min. 1 Mz
2 Between (3) and (4)
switch(Internal disconnection)
OFF Max. 1 z
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between(3) and (6) Ladder at any position Min. 1 Mz
2. Disconnect connector HR14 and connect T-adapter.
Defective parking brake solenoid
3 HR14 (male) Resistance
(Internal disconnection)
Between (1) and (2) 10 to 40 z
Between (1), (2) and ground Min. 1 Mz
2. Disconnect connectors HR17, HR18 and connect T-adapter.
HR17 (male), HR18
Parking brake pilot lamp Resistance
(male)
Defective emergency brake pres- Normal brake oil pres-
4 sure
sure switch (internal open circuit)
Min. 4.9 MPa Max. 1 z
2}
Between (1) and (2) {Min. 50 kg/cm
Low brake oil pressure
Min. 3.14 MPa Min. 1 Mz
{Max. 32 kg/cm2}
WA1200-6 40-135

2. Disconnect connectors FC04, FC09, FC17, FC18 and connect T-adapter.
Wiring harness between FC04 (female) (1) and
Max. 1 z
T18W (female) (1)
Max. 1 z
Open circuit in wiring harness HR17 (female) (1)
5
(open circuit or defective contact) Wiring harness between HR17 (female) (2) and Max. 1 z
HR18 (female) (1)
Resistance
Wiring harness between HR18 (female) (2) and
Max. 1 z
HR14 (female) (1)
Wiring harness between FC09 (female) (3) and L03
Max. 1 z
(female) (6)
Wiring harness between T18 (female) (2) and
Max. 1 z
ground
3. Start engine and perform troubleshooting
6 Defective machine monitor Parking brake oil pres-
FC04 Voltage
sure
Released Max. 1 V
Operation Max. 1 V
40-136 WA1200-6
WA1200-6 40-137
Failure code [2G42ZG] Accumulator Oil Press. F Low
Failure code [2G42ZG] Accumulator Oil Press. F Low 40-138

Action
Failure code Front brake pressure too low (when in operation)
level Failure
(KOMTRAX Plus controller system)
E03 2G42ZG
Detail of failure Front brake oil pressure drop is indicated while machine is operating
Action of con-
troller
Problem on Real-time monitor display: constantly detects minimum pressure below (0 MPa {0 kg/cm2})
q
machine q Alarm false detected
ing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the
Related infor- monitor
mation q This failure code is displayed when the brake cut-out pressure becomes lower than 14.71 MPa
{150 kg/cm2} (within the period from engine start to 60 seconds after engine start).
q When brake cut-in and cut-out pressures are normal

Front brake pressure too low or
1 defective front brake oil pressure
sensor Check if "2G42ZG" is displayed when sensor is replaced with the rear brake oil
pressure sensor (normally operating)
2. Connect T-adapters to V2A connector, JR14 connector, and each
Open circuit in wiring harness connector to be disconnected in turn.
2 (wire breakage or defective con- 3. Turn the starting switch to OFF position, then perform troubleshooting.
tact of connector) Wiring harness between V2A (female) (7) to HR15
Max. 1 z
(female) (C)
Resistance
Wiring harness between JR14 (female) (5) and
Max. 1 z
HR15 (female) (B)
2. Connect T-adapter to V2A connector and each connector to be discon-
nected in turn.
Ground fault in wiring harness 3. Turn starting switch to OFF position, then perform troubleshooting.
3
(Contact with ground circuit) Between ground and wiring harness from V2A
Min. 1 Mz
(female) (7) to HR15 (female) (C)
Resistance
Between ground and wiring harness from JR14
Min. 1 Mz
(female) (5) to HR15 (female) (B)
2. Disconnect connector V2A and connect T-adapter.
Defective KOMTRAX Plus control- 3. Turn starting switch to ON position, then perform troubleshooting.
4
ler V2A Voltage
Between (7) and (13) 0.7 – 5.3 V
40-138 WA1200-6
Failure code [2G42ZG] Accumulator Oil Press. F Low
WA1200-6 40-139
Failure code [2G43ZG] Accumulator Oil Press. R Low
Failure code [2G43ZG] Accumulator Oil Press. R Low 40-140

Action
Failure code Rear brake pressure too low (when in operation)
level Failure
E03 2G43ZG
Detail of failure Rear brake oil pressure drop is indicated while machine is operating
Action of con-
troller
Problem on Real-time monitor display: constantly detects minimum pressure below (0 MPa {0 kg/cm2})
q
Related infor- monitor
mation q This failure code is displayed when the brake cut-out pressure becomes lower than 14.71 MPa
{150 kg/cm2} (within the period from engine start to 60 seconds after engine start).
q When brake cut-in and cut-out pressures are normal

Rear brake pressure too low or 2. Start engine and perform troubleshooting.
1 defective rear brake oil pressure
sensor Check if "2G43ZG" is displayed when sensor is replaced with the front brake
oil pressure sensor (normally operating)
2. Connect T-adapters to V2A connector, JR14 connector, and each
Open circuit in wiring harness connector to be disconnected in turn.
tact of connector) Wiring harness between V2A (female) (8) and
Max. 1 z
HR16 (female) (C)
Resistance
Wiring harness between JR14 (female) (6) and
Max. 1 z
HR16 (female) (B)
2. Connect T-adapter to V2A connector and each connector to be discon-
nected in turn.
Ground fault in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
3
(Contact with ground circuit) Between ground and wiring harness from V2A
Min. 1 Mz
Resistance
Min. 1 Mz
Defective KOMTRAX Plus control- 3. Turn starting switch to ON position and perform troubleshooting.
4
ler V2A Voltage
Between (8) and (13) 0.7 – 5.3 V
40-140 WA1200-6
Failure code [2G43ZG] Accumulator Oil Press. R Low
WA1200-6 40-141
Failure code [44K0L4] Bucket cylinder position detector SW failure
Failure code [44K0L4] Bucket cylinder position detector SW failure 40-142

Action Bucket cylinder horizontal proximity switch system error (input
Failure code
level Failure signal out of range)
E01 44K0L4 (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in bucket cylinder horizontal proximity switch circuit
Action of con-
q Detail of failure is displayed in yellow on the multi-monitor screen.
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect F13 sensor, replace it with a normally operating relay, and
connect T-adapter.
1 Defective bucket positioner leveler
Replace with a normally operating
Failure code disappears
proximity switch
2. Disconnect connectors L07, F13 and connect T-adapter.
Open circuit in wiring harness Wiring harness between L07 (female) (20) and F13
2 (wire breakage or defective con- (female) (B) Max. 1 z
tact of connector) Wiring harness between L07 (female) (21) and F13
Resistance Max. 1 z
(female) (C)
Wiring harness between L05 (female) (22) and F13
Max. 1 z
(female) (A)
a Be ready with starting switch in OFF position, and perform troubleshooting
without turning stating switch to ON position.
Ground fault in wiring harness Between ground and wiring harness from L07
3 Min. 1 Mz
(contact with ground circuit) (female) (20) to F13 (female) (B)
Resistance
(female) (22) to F13 (female) (A) Min. 1 Mz
a Be ready with starting switch OFF, then turn starting switch to ON position
and perform troubleshooting.
Defective boom bucket & AJSS
4 L07 (female) Resistance
controller
40-142 WA1200-6
Failure code [7REAKA] ACC Signal Malfunction
Failure code [7REAKA] ACC Signal Malfunction 40-143

Action
Failure code ACC signal system error (input signal out of range)
level Failure
E01 7REAKA
Detail of failure Open circuit has occurred in ACC signal circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect connectors V1, L04, L07 and connect T-adapter.
Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
1 (wire breakage or defective con- Wiring harness between V1 (female) (17) and L04
(female) (14), (24)
Resistance
Wiring harness between V1 (female) (17) and L07
Max. 1 z
(female) (14), (24)
Related electrical circuit diagram 40-143
WA1200-6 40-143
Failure code [989P00] Direction protection warning
Failure code [989P00] Direction protection warning 40-14

Action
Failure code Direction protect alarm: alarm activated
level Failure
– 989P00
Detail of failure q F/R changed at improper travel speed
Action of con-
troller
Problem on
q The failure code is recorded to KOMTRAX Plus controller.
machine
Related infor-
mation

Change F/R at proper travel speed
1 Incorrect operation
(Instruct the operator on correct operation of the machine.)
Failure code [989Q00] Work equipment protection 40-14

Action
Failure code Wall surface digging prevention alarm: alarm activated
level Failure
– 989Q00
Detail of failure q Attempt to apply a load exceeding the safe level to the work equipment by digging a wall surface.
q Alarm conditions
1. Multi monitor (option settings): ON
2. At TILT end
Action of con- 3. Hinge pin height above 1.35 m
troller 4. Travel speed: below 1 km/h
5. Driving force: above 45 tons
6. Level ground: (max. 3 deg.), uphill (min. 4 deg.)
7. 2 sec. after switching F/R
Problem on
machine
Related infor-
q Lets modulation clutch slip to lower driving force and protect work equipment
mation

1 Incorrect operation (Instruct the operator on correct operation of the machine.)
40-144 WA1200-6
Failure code [989R00] Tire slip
Failure code [989R00] Tire slip 40-145

Action
Failure code Tire slip prevention control operation
level Failure
– 989R00
Detail of failure q Tire slip has occurred
q Alarm conditions
1. Travel speed: above 60 km/h
Difference in speed between right and left tires: above 4.0 km/h
Action of con- Travel speed: 1.5–4.5 km/h
troller Difference in speed between right and left tires: above 2.75 km/h
Travel speed: 1.5–4.5 km/h
Difference in speed between right and left tires: above 1.75 km/h
Difference in speed between right and left tires: above 12 km/h
Problem on
machine
Related infor-
q Decreases modulation clutch pressure to lower driving force and prevent slip
mation

WA1200-6 40-145
Failure code [989S00] Parking Brake Dragging
Failure code [989S00] Parking Brake Dragging 40-146

Action
Failure code Parking brake system error (input signal out of range)
level Failure
– 989S00
Detail of failure Open circuit has occurred in parking brake sensor circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect connectors L03, HR14, LS6 and connect T-adapter.
Wiring harness between L03 (female) (6) and HR14
Max. 1 z
Open circuit in wiring harness (female) (1)
1 (wire breakage or defective con- Wiring harness between L03 (female) (16) and LS6
Max. 1 z
tact of connector) (female) (4)
Resistance
Wiring harness between L03 (female) (26) and LS6
Max. 1 z
(female) (3)
Wiring harness between L03 (female) (36) and LS6
Max. 1 z
(female) (2)
2. Disconnect connectors L03, HR14, LS6 and connect T-adapter.
Min. 1 Mz
(female) (6) to HR14 (female) (1)
2 Min. 1 Mz
(contact with ground circuit) (female) (16) to LS6 (female) (4)
Resistance
(female) (26) to LS6 (female) (3) Min. 1 Mz

(female) (36) to LS6 (female) (2) Min. 1 Mz

L03(female) Resistance
Between (6), (16), (26), (36) and
Min. 1 Mz
ground
40-146 WA1200-6
Failure code [989S00] Parking Brake Dragging
WA1200-6 40-147
Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF)
Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF) 40-148
Action
Failure code Stationary steering detection alarm: alarm activated
level Failure
(KOMTRAX Plus controller)
– 989T00
Detail of failure q Stationary steering has been attempted
q Stationary steering detection conditions
Travel speed: below 1 km/h
Action of con- Brakes: OFF
troller Steering (frame angle deflection): Min. 10 deg/sec
Steering: Min. 10 deg./sec
No load (decided by boom bottom pressure and boom angle)
Problem on
machine
Related infor-
mation

40-148 WA1200-6
Failure code [989U00] Stationary steering (Brake: OFF, Load: ON)
Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) 40-149
Action
level Failure
– 989U00
Action of con-
Brakes: OFF
troller
Steering (frame angle deflection): Min. 10 deg/sec
Loaded (decided by boom bottom pressure and boom angle)
Problem on
machine
Related infor-
mation

WA1200-6 40-149
Failure code [989V00] Stationary steering (Brake: ON, Load: OFF)
Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) 40-150
Action
level Failure
– 989U00
Action of con-
Brakes: ON
troller
No load (decided by boom bottom pressure and boom angle)
Problem on
machine
Related infor-
mation

40-150 WA1200-6
Failure code [989W00] Stationary steering (Brake: ON, Load: ON)
Failure code [989W00] Stationary steering (Brake: ON, Load: ON) 40-151
Action
level Failure
– 989W00
Action of con-
Brakes: ON
troller
Loaded (decided by boom bottom pressure and boom angle)
Problem on
machine
Related infor-
mation

WA1200-6 40-151
Failure code [AA1ANX] Air Cleaner 1 Clogging
Failure code [AA1ANX] Air Cleaner 1 Clogging 40-152

WA1200-6
Action
Failure code Clogging of air cleaner 1
level Failure
E01 AA1ANX
Detail of failure Clogging of air cleaner 1 is indicated
Action of con-
troller
Problem on
Wrong alarm output
machine
Related infor-
mation

1 Defective dust indicator [1]
Check if indication goes out when connector (B06) of the dust indicator [1] is
disconnected.
Defective dust indicator relay [1] 2. Turn starting switch to ON position and perform troubleshooting.
2
(L132)
Check if display goes out when dust indicator relay [1] (L132) is replaced with
another relay
1. Turn starting switch to OFF position.
2. Disconnect connectors FC03, B06, L132, and connect T-adapters to each
Open circuit in wiring harness female side.
3 (wire breakage or defective con- Wiring harness between FC03 (female) (2) and
Max. 1 z
tact of connector) L132 (female) (6)
Resistance
Wiring harness between L132 (female) (3) and
Max. 1 z
ground
Ground fault in wiring harness
4 female side.
(Contact with ground circuit)
Between ground and wiring harness from B06
(female) (1) to L132 (female) (2)
2. Disconnect FC03 and connect T-adapter.
3. Turn starting switch to ON position.
5 Defective monitor panel controller FC03 Air cleaner Voltage
Normal Max 1 V
Clogged 17 – 30 V
40-152 WA1200-6
Failure code [AA1ANX] Air Cleaner 1 Clogging
WA1200-6 40-153
Failure code [AA1BNX] Air Cleaner 2 Clogging
Failure code [AA1BNX] Air Cleaner 2 Clogging 40-154

Action
level Failure
E01 AA1BNX
Action of con-
troller
Problem on
Wrong alarm output
machine
Related infor-
mation

disconnected.
2
(L133) Check if display goes out when dust indicator relay [2] (L133) is replaced with
another relay
Max. 1 z
Resistance
Max. 1 z
ground
4 female side.
Normal Max 1 V
Clogged 17 – 30 V
40-154 WA1200-6
Failure code [AA1BNX] Air Cleaner 2 Clogging
WA1200-6 40-155
Failure code [AA1CNX] Air Cleaner 3 Clogging
Failure code [AA1CNX] Air Cleaner 3 Clogging 40-156

Action
level Failure
E01 AA1CNX
Action of con-
troller
Problem on
Wrong alarm output
machine
Related infor-
mation

disconnected.
2
another relay
Max. 1 z
Resistance
Max. 1 z
ground
4 female side.
Normal Max 1 V
Clogged 17 – 30 V
40-156 WA1200-6
Failure code [AA1CNX] Air Cleaner 3 Clogging
WA1200-6 40-157
Failure code [AA1DNX] Air Cleaner 4 Clogging
Failure code [AA1DNX] Air Cleaner 4 Clogging 40-158

Action
level Failure
E01 AA1DNX
Action of con-
troller
Problem on
Wrong alarm output
machine
Related infor-
mation

disconnected.
2
another relay
Max. 1 z
Resistance
Max. 1 z
ground
4 female side.
Normal Max 1 V
Clogged 17 – 30 V
40-158 WA1200-6
Failure code [AA1DNX] Air Cleaner 4 Clogging
WA1200-6 40-159
Failure code [AB00L6] Discharge of alternator R terminal
Failure code [AB00L6] Discharge of alternator R terminal 40-160

Action
Failure code Hot short circuit in alternator R
level Failure
(Monitor panel system)
E01 AB00L6
Detail of failure q When engine is stopped, alternator terminal R input voltage is 12 V or above.
Problem on q Engine does not start
machine q Service meter reading advances by only turning starting switch to ON position.
q The input (voltage) from the alternator can be checked by using the monitoring function (Code:
Related infor-
04302, ALTERNATOR R).
mation

2. Disconnect connector E04 and connect T-adapter.
Defective alternator Alternator Engine Voltage
1
(internal defect) Start
Between terminal R (throttle opened 1/2 or 27.5 to 29.5 V
(E03) and ground more)
Stopped Max. 1 V
2. Connect T-adapter to terminal R (E04) connector and each connector to be
disconnected in turn.
Hot short circuit in wiring harness 3. Turn starting switch to ON position and perform troubleshooting.
2
Wiring harness between alternator terminal R (E03)
and FC02 (female) (18), V24 (female) (4), Voltage Max. 1 V
and circuit branch
FC02 Engine Voltage
3 Defective monitor panel
Start
(throttle opened 1/2 or 27.5 to 29.5 V
Between (18) and ground more)
Stopped Max. 1 V
40-160 WA1200-6
Failure code [AB00L6] Discharge of alternator R terminal
WA1200-6 40-161
Failure code [AB00MA] Discharge of alternator R terminal
Failure code [AB00MA] Discharge of alternator R terminal 40-162

Action
Failure code Ground fault, open circuit, or low charge voltage in alternator R
level Failure
E03 AB00MA
While the engine is running, R terminal voltage was below 5 V.
All of the following 1, 2, 3 and 4 were recognized.
1. Starting switch turned to ON (input of voltage from starting switch C terminal) is recorded
Detail of failure 2. Engine is operating normally (500 rpm or more) on CAN communication data from the engine
controller
3. Charging voltage from alternator R terminal is 5 V or less
4. The starting switch is not currently turned ON (no input of voltage from starting switch C terminal)
Action of con-
troller
Problem on
q Lowe battery charge level
machine
q A similar error is detected by KOMTRAX Plus controller as [AB00MB]
q Controller 4 pin monitors the charging voltage from the alternator (R terminal)
Related infor- Charging voltage from alternator (R terminal) is normal: Min. 12 V
mation Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V
q Alternator R terminal voltage input to the monitor panel controller can be checked with monitoring
code: 04302 (V)

1) Turn starting switch ON.
1 Defective alternator 2) Start the engine and perform troubleshooting.
Between connector E04 (5) and ground Voltage Min. 12 V
1) Turn starting switch to OFF position.
Open circuit in wiring harness 2) Disconnect connector E04.
2 (wire breakage or defective con- 3) Disconnect connector FC02, then perform troubleshooting with the connec-
tact of connector) tor remaining disconnected.
Between E04 (female) (5) and FC02 (female) (18) Resistance Max. 1 z
2) Disconnect connector E04.
Ground fault in wiring harness 3) Disconnect connector FC02, then perform troubleshooting with the connec-
3
(contact with ground circuit) tor remaining disconnected.
Between FC02 (female) (18) and ground Resistance Min. 1 Mz
If no failure is found in checks on causes 1 to 3, monitor panel controller may
4 Defective monitor panel controller be defective. (Since this is an internal defect, troubleshooting cannot be per-
formed.)
40-162 WA1200-6
Failure code [AB00MA] Discharge of alternator R terminal
WA1200-6 40-163
Failure code [AB00MB] Discharge of alternator R terminal
Failure code [AB00MB] Discharge of alternator R terminal 40-164

Action
Failure code Ground fault, open circuit, or low charge voltage in alternator R
level Failure
E03 AB00MB
q Engine is not operated normally (500 rpm or more), due to the CAN communication data with the
Detail of failure engine controller. However, the system is judged that charging voltage (R or less) from the alternator
5 V terminal is present.
Action of con-
troller
Problem on
machine
q This failure code is not displayed if CAN communication from engine controller is not possible.
q A similar error is detected by monitor panel controller as [AB00MA].
q Controller 4 pin monitors the charging voltage from the alternator (R terminal)
Related infor-
Charging voltage from alternator (R terminal) is normal: Min. 12 V
mation
Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V
q Alternator R terminal voltage input to the monitor panel controller can be checked with monitoring
code: 04302 (V)

1) Turn starting switch ON.
1 Defective alternator 2) Start the engine and perform troubleshooting.
Between connector E04 (5) and ground Voltage Min. 12 V
Open circuit in wiring harness 2) Disconnect connector E04.
2 (wire breakage or defective con- 3) Disconnect connector V2A, then perform troubleshooting with the connector
tact of connector) remaining disconnected.
Between E04 (female) (5) and V2A (female) (4) Resistance Max. 1 z
2) Disconnect connector E04.
Ground fault in wiring harness 3) Disconnect connector V2A, then perform troubleshooting with the connector
3
(contact with ground circuit) remaining disconnected.
Between V2A (female) (4) and ground Resistance Min. 1 Mz
If no failure is found in checks on causes 1 to 3, KOMTRAX Plus controller may
Defective KOMTRAX Plus control-
4 be defective. (Since this is an internal defect, troubleshooting cannot be per-
ler
formed.)
40-164 WA1200-6
Failure code [AB00MB] Discharge of alternator R terminal
WA1200-6 40-165
Failure code [B@BCZK] Drop in Engine Coolant Level
Failure code [B@BCZK] Drop in Engine Coolant Level 40-16

Action
Failure code Drop in engine coolant level
level Failure
E01 B@BCZK
Detail of failure Low coolant level is indicated
Action of con-
troller
Problem on
Low coolant level warning is output (false detection)
machine
mation monitor
q This failure code is issued before the engine is started

2. Disconnect connector GR17 and connect T-adapter.
Coolant level below low level or
defective coolant level sensor
Check if indication goes out when a jumper wire is connected between coolant
level sensor (GR17) (female) (1) and (2)
2. Connect T-adapter to connector FC04 and each connector to be discon-
nected in turn.
Open circuit in wiring harness
GR17 (female) (1)
Resistance
Wiring harness between GR17 (female) (2) and
Max. 1 z
ground
Defective joint connector JR2 or 2. Disconnect connector JR21 and connect T-adapter.
JR7
Wiring harness between JR21 (male) (6) and (1) Resistance Max. 1 z
4 Defective monitor panel controller FC04 Quantity of coolant Voltage
Normal Max 1 V
Insufficient 17 – 30 V
40-166 WA1200-6
Failure code [B@BCZK] Drop in Engine Coolant Level
WA1200-6 40-167
Failure code [b@C5ZK] Low brake fluid level (before engine start)
Failure code [b@C5ZK] Low brake fluid level (before engine start) 40-168
Action
Failure code Brake oil level too low (before engine start)
level Failure
E01 b@C5ZK
Detail of failure Low brake oil level is indicated before the engine is started
Action of con-
troller
Problem on
Warning output constantly (false detection)
machine
mation monitor
q This failure code is issued before the engine is started

Front brake oil level too low or 2. Disconnect connector HR10 and connect T-adapter.
1 defective front brake oil level sen- 3. Turn the starting switch to OFF position, then perform troubleshooting.
sor Check if indication goes out when front brake oil level sensor (HR10) (female)
(1) is grounded
Rear brake oil level too low or 2. Disconnect sensor HR6 and connect T-adapter.
2 defective rear brake oil level sen- 3. Turn the starting switch to OFF position, then perform troubleshooting.
sor Check if indication goes out when rear brake oil level sensor (HR6) (female)
(1) is grounded
2. Connect T-adapter to connector HR6 or HR10 and each connector to be
Wiring harness between V3B (female) (5) and
HR10 (female) (1)
Resistance
Wiring harness between V3B (female) (5) and HR6
Max. 1 z
(female) (1)
2. Disconnect connectors V3A, V3B and connect T-adapter.
Defective KOMTRAX Plus control- V3A, V3B Oil level Voltage
4
ler Between V3A (5) and Normal Max 1 V
ground
Between V3B (5) and Insufficient 17 – 30 V
ground
40-168 WA1200-6
Failure code [B@C5ZK] Low brake fluid level (while engine is running)
Failure code [B@C5ZK] Low brake fluid level (while engine is running) 40-169
Action
Failure code Low front or rear brake fluid level (while engine is running)
level Failure
E03 B@C5ZK
Detail of failure Low brake oil level is indicated while the engine is running
Action of con-
troller
Problem on
Warning output constantly (false detection)
machine
mation monitor
q This failure code is issued while the engine is running

Front brake oil level too low or 2. Disconnect connector HR10 and connect T-adapter.
1 defective front brake oil level sen- 3. Turn the starting switch to OFF position, then perform troubleshooting.
sor Check if indication goes out when front brake oil level sensor (HR10) (female)
(1) is grounded
Rear brake oil level too low or 2. Disconnect sensor HR6 and connect T-adapter.
2 defective rear brake oil level sen- 3. Turn the starting switch to OFF position, then perform troubleshooting.
sor Check if indication goes out when rear brake oil level sensor (HR6) (female)
(1) is grounded
2. Connect T-adapter to connector HR6 or HR10 and each connector to be
HR10 (female) (1)
Resistance
Wiring harness between V3A (female) (5) and HR6
Max. 1 z
(female) (1)
2. Disconnect connectors V3A, V3B and connect T-adapter.
Defective KOMTRAX Plus control- V3A,V3B Oil level Voltage
4
ler Between V3A (5) and Normal Max 1 V
ground
Between V3B (5) and Insufficient 17 – 30 V
ground
WA1200-6 40-169
Failure code [B@C6NS] High brake oil temp.
Failure code [B@C6NS] High brake oil temp. 40-170

Action
Failure code Brake oil overheating
level Failure
E02 B@C6NS
q Overheating of oil temperature is detected by signals from brake oil temperature sensor while engine
Detail of failure
is running.
Action of con-
q Brake oil temperature caution lamp turns ON in red.
troller
Problem on q Brake comes not to work.
machine q If machine is used as it is, brake may be damaged.
q Input signals from oil temperature sensor can be checked by using monitoring function. (Code:
Related infor-
30201( °C), 30204(V))
mation
q For troubleshooting of brake oil temperature sensor, see failure code [DGR2KX]
1 Brake cooling oil overheating Brakes may be overloaded. Check corresponding parts.
Defective brake oil temperature

2 Perform troubleshooting for failure codes [DGR2KA] and [DGR2KX].
sensor
If no failure is found in checks on causes 1 and 2, monitor panel controller may
3 Defective monitor panel controller
be defective.
40-170 WA1200-6
Failure code [b@CENS] High torque converter oil temp.
Failure code [b@CENS] High torque converter oil temp. 40-171

Action
Failure code Torque converter oil temperature is high (above 120 °C)
level Failure
E02 b@CENS
Detail of failure An overheat of torque converter oil temperature (above 120 °C) is indicated
Action of con-
troller
Problem on Torque converter oil temperature gauge constantly indicates a temperature above 120 °C
q
machine Alarm screen false output
q
Related infor-
mation
monitor

Torque converter oil temperature 3. Turn the starting switch to OFF position, then perform troubleshooting.
is above 120 °C or defective
1 T24 (male) Engine oil temperature Resistance
sensor Normal temperature
Approx. 40 z
Between (1) and (2) (25 °C)
120 °C Approx. 2.2 z
2. Disconnect connector FC05 and other connectors in turn, and connect
Ground fault in wiring harness T-adapter.
Between ground and wiring harness from FC05
Between (2) and ground Min. 1 Mz
WA1200-6 40-171
Failure code [B@CENS] Very high torque converter oil temp.
Failure code [B@CENS] Very high torque converter oil temp. 40-172
Action
Failure code Torque converter oil temperature is high (above 130 °C)
level Failure
E02 B@CENS
Detail of failure An overheat of torque converter oil temperature (above 130 °C) is indicated
Action of con-
troller
Problem on Torque converter oil temperature gauge constantly indicates a temperature above 130 °C
q
machine Alarm screen false output
q
Related infor-
mation
monitor

Torque converter oil temperature 3. Turn the starting switch to OFF position, then perform troubleshooting.
is above 120 °C or defective
1 T24 (male) Engine oil temperature Resistance
sensor Normal temperature
Approx. 40 z
Between (1) and (2) (25 °C)
130 °C Approx. 1.7 z
2. Disconnect connector FC05 and other connectors in turn, and connect
40-172 WA1200-6
Failure code [B@CENS] Very high torque converter oil temp.
WA1200-6 40-173
Failure code [B@GAZK] Low battery 1 fluid level
Failure code [B@GAZK] Low battery 1 fluid level 40-174

Action
Failure code Low battery electrolyte level [1]
level Failure
E01 B@GAZK
Detail of failure Low battery electrolyte level [1] is indicated
Action of con-
troller
Problem on
Wrong alarm output
machine
mation monitor
q When battery electrolyte level is normal

2. Disconnect connector RA9 and connect T-adapter.
Low battery charge or defective 3. Turn starting switch to ON position and perform troubleshooting.
1
battery electrolyte level sensor [1] RA9 (male) Voltage
Between (1) and ground 5.5–6.5 V
Open circuit in wiring harness 2. Disconnect connectors from V2B to RA9 in turn, and connect T-adapter.
tact of connector) Wiring harness between V2B (female) (1) and RA9
Resistance Max. 1 z
(female) (1)
2. Disconnect connectors from V2B to RA9 in turn, and connect T-adapter.
3
Between ground and wiring harness from V2B
(female) (1) to RA9 (female) (1)
2. Disconnect connector V2B and connect T-adapter.
Defective KOMTRAX Plus control- 3. Turn the starting switch to OFF position, then perform troubleshooting.
4
ler V2B (female) Resistance
40-174 WA1200-6
Failure code [B@GAZK] Low battery 1 fluid level
WA1200-6 40-175
Failure code [B@GBZK] Low battery 2 fluid level
Failure code [B@GBZK] Low battery 2 fluid level 40-176

Action
level Failure
E01 B@GBZK
Action of con-
troller
Problem on
Wrong alarm output
machine
mation monitor

1
battery electrolyte level sensor [2] R08 (male) Voltage
Between (1) and ground 5.5 – 6.5 V
Resistance Max. 1 z
(female) (1)
3
4
40-176 WA1200-6
Failure code [B@GBZK] Low battery 2 fluid level
WA1200-6 40-177
Failure code [B@GCZK] Low battery 3 fluid level
Failure code [B@GCZK] Low battery 3 fluid level 40-178

Action
level Failure
E01 B@GCZK
Action of con-
troller
Problem on
Wrong alarm output
machine
mation monitor

1
battery electrolyte level sensor [3] RA7 (male) Voltage
Between (1) and ground 5.5 – 6.5 V
Resistance Max. 1 z
(female) (1)
3
4
40-178 WA1200-6
Failure code [B@GCZK] Low battery 3 fluid level
WA1200-6 40-179
Failure code [B@HANS] High hydraulic oil temp.
Failure code [B@HANS] High hydraulic oil temp. 40-180

Action
Failure code Abnormally high hydraulic oil temperature (overheat)
level Failure
E02 B@HANS
Detail of failure An overheat of hydraulic oil temperature (above 105 °C) is indicated
Action of con-
troller
Problem on Hydraulic oil temperature gauge constantly indicates a temperature above 105 °C
q
machine Wrong alarm output
q
Related infor-
mation
monitor

2. Disconnect connector HS1 and connect T-adapter.
Hydraulic oil temperature is above HS1 (male) Engine oil temperature Resistance
1 105 °C or defective hydraulic oil Normal temperature
temperature sensor Approx. 37 – 50 kz
(25 °C)
Between (1) and (2) 100 °C Approx. 3.5 – 4.0 kz
120 °C Approx. 3.0 – 3.6 kz
2. Disconnect connector HS1 form connector FC05 in turn, and connect
(female) (7) to HS1 (female) (1)
40-180 WA1200-6
Failure code [B@HAZK] Low hydraulic oil level
Failure code [B@HAZK] Low hydraulic oil level 40-181

Action
Failure code Low hydraulic oil level
level Failure
E01 B@HAZK
Detail of failure Low hydraulic oil level is indicated while machine is operating.
Action of con-
troller
Problem on
Warning outputs constantly. (false detection)
machine
Related infor- ing, or when T-adapter is removed, connecter is restored, and no failure code is displayed on mon-
mation itor
q This failure code appears before engine is started

Low oil level or defective hydraulic
oil level sensor
Check if indication goes out when hydraulic oil level sensor (HS5) (female) (1)
is grounded.
nected in turn.
3. Turn starting switch to OFF position, then perform troubleshooting.
tact of connector)
Between wiring harnesses between FC04 (female)
Resistance Max. 1 z
(2) and HS5 (female) (1)
2. Disconnect FC04 connector and connect T-adapter.
3 Defective monitor panel controller FC04 Oil level Voltage
Between FC04 (2) and Normal Max 1 V

ground Insufficient 17 to 30 V
WA1200-6 40-181
Failure code [D191KA] Neutral Output Relay Disconnection
Failure code [D191KA] Neutral Output Relay Disconnection 40-182

Action
Failure code AJSS neutral safety relay: open circuit
level Failure
(Boom bucket & AJSS controller system)
E01 D191KA
q Signal is not output to neutral safety relay due to open circuit in AJSS neutral safety relay output
Detail of failure
system
Action of con-
q If cause of failure disappears, machine becomes normal by itself.
troller
Problem on q While operating AJSS lever, engine can be started (steering moves immediately after engine
machine starts)
q The neutral safety relay does not function if the AJSS neutral position adjustment (initial setting)
Related infor-
has not been performed
mation
q Method of reproducing failure code: Operate AJSS lever while engine is stopped

Defective AJSS neutral safety
1 relay (L127)
(Internal open circuit) L127 (male) Resistance
2. Disconnect connectors L07, L127 and connect T-adapter.
Hot short circuit in wiring harness
2 Between ground and wiring harness from L07
(contact with power supply circuit) Voltage Max. 1 V
Resistance Max. 1 z
ground
2. Disconnect connectors L03 in turn and connect T-adapter.
Defective boom bucket & AJSS 3. Turn starting switch to ON position and perform troubleshooting.
3
controller L07 Voltage
Between (4) and ground 20 to 30 V
40-182 WA1200-6
Failure code [D191KA] Neutral Output Relay Disconnection
WA1200-6 40-183
Failure code [D191KB] Neutral Output Relay hot short
Failure code [D191KB] Neutral Output Relay hot short 40-184

Action
Failure code AJSS neutral safety relay: short circuit
level Failure
E01 D191KB
Detail of failure q Abnormal current flows because of ground fault in AJSS neutral safety relay output system.
q Turns the output to the AJSS neutral safety relay OFF.
Action of con-
troller
to OFF position.
Problem on q While operating AJSS lever, engine can be started (steering moves immediately after engine
machine starts)
q The neutral safety relay does not function if the AJSS neutral position adjustment (initial setting)
Related infor- has not been performed
mation q While an error is occuring the controller does not output power.
q Method of reproducing failure code: Operate AJSS lever while engine is stopped

Defective AJSS neutral safety 3. Turn the starting switch to OFF position, then perform troubleshooting.
1 relay (L127) L127 (male) Resistance
2. Disconnect connectors L02-127 and connect T-adapter.
2
2. Disconnect connectors L03 in turn and connect T-adapter.
3
40-184 WA1200-6
Failure code [D191KB] Neutral Output Relay hot short
WA1200-6 40-185
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit)
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short

Circuit) 40-186
Action
Failure code Switch pump PNC solenoid relay: open circuit, ground fault
level Failure
E01 D19MKA
Due to open circuit or ground fault in the switch pump PNC solenoid system, no current flows when
Detail of failure
the switch pump PNC solenoid is energized.
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Disconnect L69 relay, replace with a normally operating relay, and connect
Defective switch pump PNC sole- T-adapter.
1
noid relay (internal open circuit) 3. Turn starting switch to ON position and perform troubleshooting.
relay.
2. Disconnect connectors L06, HR31, HR32 and connect T-adapter.
2 (wire breakage or defective con- Wiring harness between L06 (female) (16) and
HR32 (female) (1)
Resistance
Max. 1 z
HR31 (female) (1)
3 Min. 1 Mz
(Contact with ground circuit) (female) (16) to HR32 (female) (1)
Resistance
(female) (26) to HR31 (female) (1) Min. 1 Mz

Defective boom bucket & AJSS 3. Turn the starting switch to OFF position, then perform troubleshooting.
4
controller L06 (female) Resistance
40-186 WA1200-6
Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit)
WA1200-6 40-187
Failure code [D19MKY] SW pump PNC solenoid Relay hot short
Failure code [D19MKY] SW pump PNC solenoid Relay hot short 40-18
Action
Failure code Switch pump PNC solenoid relay: hot short circuit
level Failure
E01 D19MKY
Detail of failure Hot short circuit has occurred in switch pump PNC solenoid system
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Disconnect relay L69 and replace with a normally operating relay.
Defective switch pump PNC sole-
noid relay (internal short circuit)
relay.
Hot short circuit in wiring harness Between ground and wiring harness from L06
2 Max. 1 V
(contact with 24 V circuit) (female) (16) to HR32 (female) (1)
Voltage
(female) (26) to HR31 (female) (1) Max. 1 V

3
40-188 WA1200-6
Failure code [D19MKY] SW pump PNC solenoid Relay hot short
WA1200-6 40-189
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure 40-190

Action
Failure code Switch pump PNC solenoid 1: ground fault, or hot short circuit
level Failure
E01 D19MMA
Detail of failure An error has occurred in switch pump PNC solenoid system
Action of con-
troller
Problem on
machine
Related infor-
mation

Defective switch pump PNC sole- 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
noid 1 (internal open circuit) HR31 (male) Resistance
Between (1) and (2) 5–15 z
2. Disconnect connectors L06, HR31 and connect T-adapter.
HR31 (female) (1)
Resistance
Max. 1 z
JR3 (female) (1)
3
4 Max. 1 V
Voltage
Between ground and wiring harness from HR31
(female) (2) to JR3 (female) (3) Max. 1 V

5
40-190 WA1200-6
Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure
WA1200-6 40-191
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure 40-192

Action Switch pump PNC solenoid 2: open circuit, ground fault, or hot
Failure code
level Failure short circuit
E01 D19MMB (Boom bucket & AJSS controller system)
Detail of failure An error has occurred in switch pump PNC solenoid system
Action of con-
troller
Problem on
machine
Related infor-
mation

Defective switch pump PNC sole-
1 R32 (male) Resistance
noid 2 (internal short circuit)
HR32 (female) (1)
Resistance
Max. 1 z
JR3 (female) (4)
3
4 Max. 1 V
Voltage
Between ground and wiring harness from HR32
(female) (2) to JR3 (female) (4) Max. 1 V

5
40-192 WA1200-6
Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure
WA1200-6 40-193
Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)
Failure code [D5ZHKA] Starting Switch C signal circuit (Discon-

nect/Short Circuit) 40-194
WA1200-6
Action
Failure code Terminal C signal: open circuit, ground fault
level Failure
E01 B5ZHKA
q Open circuit or ground fault in terminal C system (engine speed is above 500 rpm rpm and no start-
Detail of failure
ing switch terminal C signal has been input.)
Action of con- q None in particular
Problem on
q The engine does not start.
machine
q Input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
Related infor-
with monitoring function (Code: 40905 D-IN-7) (Transmission controller system).
mation
q Method of reproducing failure code: Set the starting switch to START position
1 Defective fuse (1) If fuse is blown, circuit may have ground fault. (See cause 4.)

2. Disconnect connector FCL1 and connect T-adapter.
3. Turn starting switch to ON, OFF, and START positions to perform trouble-
Defective starting switch shooting.
2
(Internal open circuit) FCL1 Starting switch Resistance
START Max. 1 z
Between (1) and (6)
OFF, ON Min. 1 Mz
2. Disconnect each connector and connect T-adapter.
Open circuit in wiring harness Wiring harness between FCL1 (female) (5) and L57
Max. 1 z
3 (wire breakage or defective con- (female) (5)
tact of connector) Wiring harness between L57 (female) (3) and L127
Resistance Max. 1 z
(female) (6)
Wiring harness between L127 (female) (3) to L02
Max. 1 z
(female) (6)
Between ground and wiring harness from FCL1
(female) (5) to L57 (female) (5), and to circuit Min. 1 Mz
Ground fault in wiring harness branch end
4
(contact with ground circuit) Between ground and wiring harness from L57
(female) (3) to L127 (female) (3), and to circuit Resistance Min. 1 Mz
branch end
(female) (3) to L02 (female) (6), and to circuit Min. 1 Mz
branch end point
shooting.
L02 Starting switch Voltage
START 20 to 30 V
OFF, ON Max. 1V
40-194 WA1200-6
Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)
WA1200-6 40-195
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short 40-196
Action
Failure code Terminal C signal: hot short circuit
level Failure
E01 B5ZHKB
q Hot short circuit in terminal C system (engine speed is above 500 rpm and starting switch terminal
Detail of failure
C signal has been input.).
Action of con- q Stops engine starting aid function.
Problem on
machine
q Input state (ON/OFF) from starting switch terminal C to transmission controller can be checked
Related infor-
with monitoring function (Code: 40905 D-IN-7) (Transmission controller system).
mation

1
START Max. 1 z
Between (1) and (6)
OFF, ON Min. 1 Mz
(female) (5) to L57 (female) (5), and to circuit Max. 1 V
Hot short circuit in wiring harness branch end
2
(contact with 24 V circuit) Between ground and wiring harness from L57
(female) (3) to L127 (female) (6), and to circuit Voltage Max. 1 V
branch end
branch end point
shooting.
L02 Starting switch Voltage
START 20 to 30 V
OFF, ON Max. 1 V
40-196 WA1200-6
Failure code [D5ZHKB] Starting Switch C signal circuit Hot short
WA1200-6 40-197
Failure code [D5ZHKZ] Starting Switch C signal circuit failure
Failure code [D5ZHKZ] Starting Switch C signal circuit failure 40-198

Action
Failure code Terminal C signal: short circuit
level Failure
(Work equipment controller system)
E01 B5ZHKZ
q Hot short circuit in terminal C system (engine speed is above 500 rpm and starting switch terminal
Detail of failure
C signal has been input.).
Action of con- q Stops engine starting aid function.
Problem on
machine
q Input condition (ON/OFF) to work equipment controller from starting switch terminal C can be
Related infor-
checked with monitoring function (Code: 40905 D-IN-7) (Work equipment controller system).
mation

1
START Max. 1 z
Between (1) and (6)
OFF, ON Min. 1 Mz
Hot short circuit in wiring harness branch end
2
(female) (3) to L127 (female) (6), and to circuit Voltage Max. 1 V
branch end
branch end point
Defective work equipment control- shooting.
3
ler L06 Starting switch Voltage
START 20 to 30 V
OFF, ON Max. 1 V
40-198 WA1200-6
Failure code [D5ZHKZ] Starting Switch C signal circuit failure
WA1200-6 40-199
Failure code [D5ZHL6] Ignition C terminal Circuit Failure
Failure code [D5ZHL6] Ignition C terminal Circuit Failure 40-20

Action
Failure code Prelubrication system error (input signal out of range)
level Failure
E01 D5ZHL6
Detail of failure Open circuit or ground fault has occurred in prelubrication system
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect the following connectors and connect T-adapter.
Open circuit in wiring harness Wiring harness between FC02 (female) (2) and
Max. 1 z
1 (wire breakage or defective con- FCL1 (6) and L127 (female) (3)
tact of connector) Wiring harness between starting switch (BR) and
LR11 (female) (1) Resistance Max. 1 z
Wiring harness between starting switch (C) and L57

(female) (5) Max. 1 z

2. Disconnect the following connectors and connect T-adapter.
Min. 1 Mz
Ground fault in wiring harness (female) (2) to FCL1 (6) and to L127 (female) (3)
2
(contact with ground circuit) Between ground and wiring harness from starting
switch (BR) to LR11 (female) (1) Resistance Min. 1 Mz
Between ground and wiring harness from starting

switch (C) to L57 (female) (5) Min. 1 Mz
40-200 WA1200-6
Failure code [D5ZHL6] Ignition C terminal Circuit Failure
WA1200-6 40-201
Failure code [DAF5KP] Monitor Panel 5 V source sys Error
Failure code [DAF5KP] Monitor Panel 5 V source sys Error 40-202

Action
Failure code Lift arm angle sensor power supply error
level Failure
E01 DAF5KP
Detail of failure Ground fault has occurred in lift arm angle sensor power supply circuit
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Disconnect connectors FC01, F04 and connect T-adapter.
1
(female) (16) to FC04 (female) (C)
FC01 Voltage
(16)–(6) Min. 4.5 – 5 V
40-202 WA1200-6
Failure code [DAF5KP] Monitor Panel 5 V source sys Error
WA1200-6 40-203
Failure code [DAFRKR] Communication Lost Monitor Panel Controller
Failure code [DAFRKR] Communication Lost Monitor Panel Controller 40-204

Action
Failure code CAN-NET signal communication error (monitor panel controller)
level Failure
E03 DAFRKR
q Communication via CAN signal line between the machine monitor and transmission controller is
Detail of failure
defective.
q Uses CAN information that was sent from monitor panel controller before the occurrence of the er-
Action of con- ror.
troller q Turns the centralized warning lamp and alarm buzzer ON.
Problem on
q The monitor does not display normally
machine
Related infor-
mation

2. Connect T-adapter between connectors FC06 and L03.
FC06 (female) (8)
Resistance
Max. 1 z
FC06 (female) (3)
2. Disconnect connectors between FC06 and L03 in turn and connect
T-adapter.
(contact with ground circuit) Min. 1 Mz
(female) (22) to FC06 (female) (8)
Resistance
Min. 1 Mz
T-adapter.
(contact with 24 V circuit) Max. 1 V
Voltage
Max. 1 V
Contact with wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
4
(Between CANH and CANL) FC06 (female) Resistance
Between (3) and (8) Min. 1 Mz
2. Disconnect connector CAN1 and connect T-adapter.
5 Defective terminationg resistance
CAN1 (male) Resistance
Between (A) and (B) 120 ± 12 z
a If no failure is found in above diagnoses for causes 1 to 5, monitor panel
6 Defective monitor panel controller controller may be defective. (Since this is an internal defect, troubleshoot-
ing cannot be performed.)
40-204 WA1200-6
Failure code [DAFRKR] Communication Lost Monitor Panel Controller
WA1200-6 40-205
Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source
Failure code [DAQ0KK] Drop in Transmission Controller Main Power

Source 40-206
Action
Failure code Transmission controller: Power supply voltage drop
level Failure
E03 DAQ0KK
q Unswitched power supply voltage (power supply directly from battery) of the transmission control-
ler drops.
Detail of failure
q Voltage of UNSW power supply (battery direct power supply) is below 18 V and engine speed is
500 rpm or more.
q Cannot detect the input signals correctly.
Action of con-
troller
Problem on
q The machine cannot operate normally.
machine
Related infor-
mation

Circuit breaker (CBF4, CBF8) If the circuit breaker is open, the circuit probably has ground fault, etc. (See
1
open Cause No. 4.)
2 Blown fuse 1-4 or fuse 2-8 If fuse is blown, circuit may have ground fault. (See cause 4.)

2. Connect T-adapter to battery relay and each connector to be disconnected
in turn.
Wiring harness between LH battery relay circuit
breaker CBF4 and RH battery relay circuit breaker Max. 1 z
CB8
tact of connector)
Wiring harness between circuit breaker CBF4 fuse Resistance
Max. 1 z
2 and circuit breaker CBF8 fuse 1
Wiring harness between fuse 2 (8) L04 (female) (2),
Max. 1 z
fuse 1 (4) L04 (female) (1), and circuit branch end
in turn.
Ground fault in wiring harness breaker CBF4 and RH battery relay circuit breaker Min. 1 Mz
4 CB8
Wiring harness between circuit breaker CBF4 fuse Resistance

Min. 1 Mz

Min. 1 Mz
2. Disconnect connector L04 and connect T-branch.
L04 Voltage
Between (1), (11) and ground
20 to 30 V
Between (2), (12), (22) and ground
40-206 WA1200-6
Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source
WA1200-6 40-207
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal 40-208

Action
Failure code Nonvolatile memory (EEPROM) writing error
level Failure
E01 DAQ0KT
Detail of failure Internal failure of transmission controller.
Action of con-
Interrupts learning and uses default data.
troller
Problem on
Gear shifting shocks.
machine
a Condition is restored if no failure code is displayed on monitor when connector is disconnected and
Related infor-
T-adapter is inserted or when T-adapter is removed, connecter is restored as troubleshooting is
mation
made while failure is appearing.
1 Defective transmission controller Gearshift shock is reduced by learning.
40-208 WA1200-6
Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal
WA1200-6 40-209
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power

Source 40-210
Action
Failure code Controller solenoid powersupply voltage drop
level Failure
E03 DAQ2KK
Detail of failure Controller solenoid powersupply voltage has dropped
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect connectors L04, AL3, AR4 and connect T-adapter.
(wire breakage or defective con-
tact of connector) Wiring harness between L04 (female) (2) and AL3 Max. 1 z
Resistance
Wiring harness between L04 (female) (1) and AR4 Max. 1 z
(female) (2) to AL3
Resistance
Min. 1 Mz
(female) (1) to AR4
Short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
3
(contact between harnesses)
Wiring harness between L04 (female) (2) and AL3,
and between L04 (female) (1) and AR4
(connection with 24 V circuit) Max. 1 V
(female) (2) to AL3
Voltage
Max. 1 V
(female) (1) to AR4
L04 (female) Voltage
Between (1), (2) and ground Max. 1 V
40-210 WA1200-6
Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source
WA1200-6 40-211
Failure code [DAQRKR] Communication Lost T/M Controller
Failure code [DAQRKR] Communication Lost T/M Controller 40-212

Action
Failure code CAN-NET signal communication error (transmission controller)
level Failure
E03 DAQRKR
q Communication via CAN signal line between the machine monitor and transmission controller is
Detail of failure
defective.
q For CAN information from transmission controller, uses lase value obtained before failure.
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Connect T-adapter between connectors FC06 and L03.
Max. 1 z
tact of connector) FC06 (female) (8)
Resistance
Max. 1 z
FC06 (female) (3)
T-adapter.
Resistance
Min. 1 Mz
T-adapter.
Voltage
Max. 1 V
4
(Between CANH and CANL) FC06 (female) Resistance
a If no failure is found by above diagnoses on causes 1 to 5, transmission
6 Defective transmission controller controller may be defective. (Since this is an internal defect, troubleshoot-
40-212 WA1200-6
Failure code [DAQRKR] Communication Lost T/M Controller
WA1200-6 40-213
Failure code [DAQRMA] Defective Option Selection Data in Transmission
Failure code [DAQRMA] Defective Option Selection Data in Transmis-

sion 40-214
Action
Failure code Option setting for transmission controller: Malfunction
level Failure
(Machine monitor - transmission controller)
E03 DAQRMA
q Option settings information sent from machine monitor when starting switch is turned to ON posi-
Detail of failure
tion differ from option settings stored in controller.
q Gear speed is held in Neutral.
Action of con-
q Option settings stored in controller are used for control.
troller
q Condition is not recovered until starting switch is turned to OFF position.
Problem on
q Gear speed is set to Neutral and restart becomes unable.
machine
Related infor- q Perform initial setting and initial adjustments in the same way when replacing the transmission con-
mation troller.

Defective setting of transmission
1 Defective setting of transmission controller options
controller
40-214 WA1200-6
Failure code [DAQRMA] Defective Option Selection Data in Transmission
WA1200-6 40-215
Failure code [DB2RKR] Communication Lost Engine Controller
Failure code [DB2RKR] Communication Lost Engine Controller 40-216

Action CAN communication with transmission controller: communica-
Failure code
level Failure tion failure (failure in target component system)
E03 DB2RKR (Transmission controller - engine controller system)
Detail of failure q Communication failure in CAN signal line between engine controller and transmission controller
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Connect T-adapter between connectors L06 and E3.
1 (wire breakage or defective con- Wiring harness between L03 (female) (22) and E3
Max. 1 z
tact of connector) (female) (A)
Resistance
Wiring harness between L03 (female) (32) and E3
Max. 1 z
(female) (B)
2. Disconnect connectors between L06 and E3 in turn and connect T-adapter.
2 Min. 1 Mz
(contact with ground circuit) (female) (22) to E3 (female) (A)
Resistance
(female) (32) to E3 (female) (B) Min. 1 Mz

2. Disconnect connectors between L06 and E3 in turn and connect T-adapter.
3 Max. 1 V
(contact with 24 V circuit) (female) (22) to E3 (female) (A)
Voltage
(female) (32) to E3 (female) (B) Max. 1 V

2. Disconnect connector E3 and connect T-adapter.
4
(Between CANH and CANL) E3 (female) Resistance
Between (A) and (B) Min. 1 Mz
40-216 WA1200-6
Failure code [DB2RKR] Communication Lost Engine Controller
WA1200-6 40-217
Failure code [DB90KK] Drop in Work Controller Main Power Source
Failure code [DB90KK] Drop in Work Controller Main Power Source 40-218
Action
Failure code Work equipment controller: low power supply voltage (input)
level Failure
(Work equipment controller system)
E03 DB90KK
q Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
Detail of failure
q Voltage of UNSW power supply (battery direct power supply) is 18 V or less.
q Do not display failure codes other than this code if voltage of UNSW power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of con- q Even if cause of failure disappears, machine does not become normal until AJSS lever and work
troller equipment control lever are set to N (NEUTRAL).
q Normal operation is impossible because it cannot detect the input signals correctly.
Problem on
q The machine cannot operate normally.
machine
Related infor-
mation

Circuit breaker (CBF4, CBF8) If the circuit breaker is open, the circuit probably has ground fault, etc. (See
1
open Cause No. 4.)
2 Blown fuse 1-4 or fuse 2-8 If fuse is blown, circuit may have ground fault. (See cause 4.)

in turn.
breaker CBF4 and RH battery relay circuit breaker Max. 1 z
CB8
tact of connector)
Wiring harness between circuit breaker CBF4 fuse
Resistance Max. 1 z
fuse 1 (4) L07 (female) (1), and circuit branch end Max. 1 z

in turn.
Ground fault in wiring harness breaker CBF4 and RH battery relay circuit breaker Min. 1 Mz
4 CB8
Wiring harness between circuit breaker CBF4 fuse
Resistance
2 and circuit breaker CBF8 fuse 1 Min. 1 Mz

Min. 1 Mz
2. Disconnect connector L07 and connect T-branch.
Defective work equipment control- 3. Turn starting switch to ON position and perform troubleshooting.
5
ler L07 Voltage
Between (1), (11) and ground
20 to 30 V
Between (2), (12), (22) and ground
40-218 WA1200-6
Failure code [DB90KK] Drop in Work Controller Main Power Source
WA1200-6 40-219
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal 40-2 0

Action Boom bucket & AJSS controller non-volatile memory: internal
Failure code
level Failure failure of controller
E01 DB90KT (Boom bucket & AJSS controller system)
Detail of failure q Error occurs in non-volatile memory of controller.

q Controls machine by applying default values to machine model selection and option settings.
Action of con- q Detail of failure is displayed in yellow on the multi-monitor screen.
troller q Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Problem on q Errors may be detected wrongly.
machine q Performance lowers because work equipment is controlled by improper data.
Related infor-
mation

Defective boom bucket & AJSS Since this is internal failure, troubleshooting cannot be performed.
1
controller Replace controller.
40-220 WA1200-6
Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal
WA1200-6 40-221
Failure code [DB92KK] Solenoid Voltage Failure (Work controller)
Failure code [DB92KK] Solenoid Voltage Failure (Work controller) 40-2 2

Action
Failure code Controller solenoid powersupply voltage drop
level Failure
E03 DB92KK
Detail of failure Controller solenoid powersupply voltage has dropped
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect connectors L07, AR4, AL3 and connect T-adapter.
(wire breakage or defective con-
tact of connector) Wiring harness between L07 (female) (1) and AR4 Max. 1 z
Resistance
Wiring harness between L07 (female) (2) and AL3 Max. 1 z
(female) (2) to AL3
Resistance
Min. 1 Mz
(female) (1) to AR4
Short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
3
(contact between harnesses)
Wiring harness between L07 (female) (1) and AR4,
and between L07 (female) and AL3
(connection with 24 V circuit) Max. 1 V
(female) (2) to AL3
Voltage
Max. 1 V
(female) (1) to AR4
5
controller L07 (female) Voltage
Between (1), (2) and ground Max. 1 V
40-222 WA1200-6
Failure code [DB92KK] Solenoid Voltage Failure (Work controller)
Related electrical circuit diagram 40-2 3
WA1200-6 40-223
Failure code [DB95KX] 5 V source sys Error (Work controller)
Failure code [DB95KX] 5 V source sys Error (Work controller) 40-2 4

Action
Failure code Sensor 5 V power supply (1) input signal out of range
level Failure
E03 DB95KX
Detail of failure q 5 V sensor power supply system is out of normal voltage output range (outside 4.7 to 5.3 V)
q Input signals cannot be sensed properly due to failure of potentiometer signal.
Action of con-
troller
Problem on q The work equipment does not work at all.
machine q The potentiometer errors described below occur.
Related infor-
mation

2. Disconnect connector R32 and connect T-adapter.
Defective frame angle potentiome- 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
ter (internal open or short circuit) R32 (male) Resistance
Between (B) and (C) 4–6 kz
2. Disconnect connector S30 and connect T-adapter.
Defective AJSS lever potentiome- 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
ter (internal open or short circuit) S30 (male) Resistance
Defective lift arm EPC lever poten-
3 tiometer
tor (internal open or short circuit) S03 (male) Resistance
Between (4) and (1) 2.5–3.9 kz
Defective bucket EPC lever poten-
4 tiometer
tor (internal open or short circuit) S02 (male) Resistance
Between (4) and (1) 2.5–3.9 kz
ground
6
Between (22) and (10) 4.85 to 5.15 V
40-224 WA1200-6
Failure code [DB95KX] 5 V source sys Error (Work controller)
WA1200-6 40-225
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick
Controller 40-2 6
Action CAN communication with transmission controller: communica-
Failure code tion failure
level
Failure (abnormality in objective component system)
E03 DB9RKR (Transmission controller - boom bucket & AJSS controller sys-
tem)
q Communication via CAN signal line between the boom bucket & AJSS controller and transmission
Detail of failure
controller is defective
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Connect T-adapter between connectors L03 and L06.
1 (wire breakage or defective con- Wiring harness between L03 (female) (22) and L06
Max. 1 z
Resistance
Wiring harness between L03 (female) (32) and L06
Max. 1 z
(female) (3)
2. Disconnect connectors between L03 and L06 in turn and connect
T-adapter.
(female) (22) and L06 (female) (22)
Resistance
(female) (32) and L06 (female) (3) Min. 1 Mz

2. Disconnect connectors between L03 and L06 in turn and connect
T-adapter.
Voltage
(female) (32) and L06 (female) (3) Max. 1 V

4
(Between CANH and CANL) L06 (female) Resistance
40-226 WA1200-6
Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller
WA1200-6 40-227
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket

Controller 40-2 8
Action
Failure code Boom bucket & AJSS controller option setting: malfunction
level Failure
(Machine monitor - boom bucket & AJSS controller)
E03 DB9RMA
q Option setting information sent from machine monitor when starting switch is turned to ON position
Detail of failure
differs from option setting stored in controller.
q Option settings stored in controller are used for control.
Action of con-
troller
q Condition is not recovered until starting switch is turned to OFF position.
Problem on
machine
Related infor- q Perform initial setting and initial adjustments in the same way when replacing boom bucket & AJSS
mation controller.

Defective setting of boom bucket
1 Defective setting of boom bucket & AJSS controller options
& AJSS controller
40-228 WA1200-6
Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller
WA1200-6 40-229
Failure code [DB9RMC] Communication Lost (Work Controller)
Failure code [DB9RMC] Communication Lost (Work Controller) 40-230

Action
Failure code CAN communication malfunction
level Failure
E03 DB9RMC
q Communication via CAN signal line between the boom bucket & AJSS controller and transmission
Detail of failure
controller is defective
q Uses CAN information that was sent from boom bucket controller before the occurrence of the er-
Action of con- ror.
Problem on
machine
Related infor-
mation

1
(wire breakage or defective con- Wiring harness between L03 (female) (22) and L06
(female) (22)
Resistance
Max. 1 z
(female) (32)
Resistance
Min. 1 Mz
3 Max. 1 V
(connection with 24 V circuit) (female) (22) and L06 (female) (22)
Voltage
Max. 1 V
4
(Between CANH and CANL) L06 (female) Resistance
a If no failure is found in above diagnoses for causes 1 to 5, boom bucket &
6 AJSS controller may be defective. (Since this is an internal defect, trouble-
controller
shooting cannot be performed.)
40-230 WA1200-6
Failure code [DB9RMC] Communication Lost (Work Controller)
WA1200-6 40-231
Failure code [DBB0KK] VHMS source voltage Error
Failure code [DBB0KK] VHMS source voltage Error 40-232

Action
Failure code KOMTRAX Plus power supply abnormal
level Failure
E03 DBB0KK
Detail of failure Power supply circuit voltage dropped while KOMTRAX Plus engine speed is above 500 rpm.
Action of con-
troller
When there is an open circuit
Problem on Data cannot be saved (problem occurs when both of 2 wires are open)
q
machine When there is a hot short circuit
q No failure symptom
q When fuse I (10) is not blown (if blown, check wiring harness between fuse and KOMTRAX Plus
Related infor- for ground fault)
mation q Open circuit in KOMTRAX Plus ground line harness is unlikely to occur since there are multiple
poles. Exclude it from probable causes

2. Connect T-adapter to connector V1 and each connector to be disconnected
Open circuit in wiring harness in turn.
tact of connector) Wiring harness between V1 (female) (6) - FS1 (10)
- fuse - FS1 (1) - battery relay terminal (AL04) - bat- Resistance Max. 1 z
tery (+)
in turn.
Between ground and wiring harness V1 (female) (6)
- FS1 (10) - fuse - FS1 (1) - battery relay terminal Voltage 20 – 30 V
(AL04) - battery (+)
2. Disconnect connector V1 and connect T-adapter.
3
ler V1 Voltage
Between (6), (7) and ground 20 – 30 V
40-232 WA1200-6
Failure code [DBB0KK] VHMS source voltage Error
WA1200-6 40-233
Failure code [DBB0KQ] VHMS Connector Mismatch
Failure code [DBB0KQ] VHMS Connector Mismatch 40-234

Action
Failure code Improper connection of KOMTRAX Plus select connector
level Failure
E03 DBB0KQ
Detail of failure Disagreement of model selection signals occurs.
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Disconnect connector JR21 and connect T-adapter.
1 Defective joint connector (JR21) 3. Turn the starting switch to OFF position, then perform troubleshooting.
Between each pin of JR21 (male) Resistance Max. 1 z
2. Connect T-adapter to connector V2B, V3A and each connector to be
Open circuit in wiring harness disconnected in turn.
tact of connector)
Between wiring harnesses between V2B (female)
(12), V3A (female) (9) and RA4 (female) (1)
2. Connect T-adapter to connector V2B, V3A and each connector to be
Ground fault in wiring harness disconnected in turn.
3
(Contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting.
Resistance Min1 Mz
(female) (12), V3A (female) (9) to RA4 (female) (1)
40-234 WA1200-6
Failure code [DBB0KQ] VHMS Connector Mismatch
WA1200-6 40-235
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V)
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V)40-236

Action
Failure code Backup power supply for KOMTRAX Plus abnormal
level Failure
E03 DBB3KK
Detail of failure Voltage drop occurs in KOMTRAX Plus backup power supply circuit.
Action of con-
troller
Problem on
machine
q When fuse I (10) is not blown (if blown, check wiring harness between fuse and KOMTRAX Plus
Related infor- for ground fault)
mation q Open circuit in KOMTRAX Plus ground line harness is unlikely to occur since there are multiple
poles. Exclude it from probable causes

Open circuit in wiring harness in turn.
tact of connector) Wiring harness between V1 (female) (6) (7) - FS1
(10) - fuse - FS1 (1) - battery relay terminal (AL04) - Resistance Max. 1 z
battery (+)
in turn.
Between ground and wiring harness V1 (female) (6)
(7) - FS1 (10) - fuse - FS1 (1) - battery relay termi- Resistance Min. 1 Mz
nal (AL04) - battery (+)
in turn.
ler
V1 Voltage
Between (6), (7) and ground 20 to 30 V
40-236 WA1200-6
Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V)
WA1200-6 40-237
Failure code [DBB5KP] VHMS 5 V source sys Error
Failure code [DBB5KP] VHMS 5 V source sys Error 40-238

Action
Failure code KOMTRAX Plus sensor power supply (5 V) abnormal
level Failure
E01 DBB5KP
Detail of failure Low output voltage appears in KOMTRAX Plus sensor power supply (5 V) circuit.
Action of con- q Interrupts output
troller q Detail of failure is displayed in yellow on the multi-monitor screen.
Problem on
Value of sensor using power supply abnormal
machine
Related infor-
mation

Defective transmission lubricating 2. Perform troubleshooting as is.
1
oil pressure sensor Check if indication goes out when transmission lubricating oil temperature
sensor (MT1) is disconnected.
2. Disconnect connectors V1, MT1 and connect T-adapter.
Ground fault in wiring harness 3. Perform troubleshooting with starting switch left in OFF position.
2
Between ground and wiring harness between V1
(female) (4) and MT1 (female) (B)
2. Disconnect V1 and connect T-adapter.
3
ler V1 Voltage
40-238 WA1200-6
WA1200-6 40-239

Action
level Failure
E01 DBB6KP
Detail of failure Low output voltage appears in KOMTRAX Plus sensor power supply (24 V) circuit
Problem on
machine
Related infor-
mation

2. Disconnect each connector
Sensor that caused indication to
go out is defective
Check if indication goes out when sensor MT2, 3, 4, HR15, 16, HS3, or 4 is
disconnected individually
2. Disconnect each connector
Defective joint connector (JT2,
2 3. Perform troubleshooting as is
JR14, or JL2)
Between pins JT2 (male), JR14 (male), and JR3
Resistance Max. 1 z
(male)
2. Disconnect corresponding connector and connect T-adapter.
3. Perform troubleshooting with starting switch left in OFF position
Between ground and wiring harness from JL2
(female) (4) to JT2 (female) (1), or from JL2 Min. 1 Mz
Ground fault in wiring harness (female) (5) to JR14 (female) (1)
3 Between ground and wiring harness from JT2
(female) (2), (3), (4), (5) to MT4 (female) (2), MT3 Min. 1 Mz
Resistance
(female) (2), MT2 (female) (2)
(female) (2), (3), (4), (5), (6) to HS4 (female) (2),
Min. 1 Mz
HS3 (female) (2), HR16 (female) (2), HR15
(female) (2)
4
ler V1 Voltage
Between (2) and ground 22–25 V
40-240 WA1200-6
WA1200-6 40-241
Troubleshooting by failure co

Troubleshooting by failure co 40-242
WA1200-6
Action
level Failure
E01 DBB7KP
Detail of failure Low output voltage appears in KOMTRAX Plus sensor power supply (12 V) circuit.
Problem on
machine
Related infor-
mation

1 Defective wheel speed sensor 2. Turn starting switch to ON position and perform troubleshooting.
Check if indication goes out when wheel speed sensor (F15) is disconnected.
2. Disconnect connectors V1, FL2, F15 and connect T-adapter in turn.
(female) (3) and F15 (female) (1)
3
ler V1 Voltage
40-242 WA1200-6
Failure code [DBBQMC] Communication Lost (VHMS CAN0)
Failure code [DBBQMC] Communication Lost (VHMS CAN0) 40-243

Action
level Failure
E03 DBBQMC
q Communication via CAN signal line between the KOMTRAX Plus controller and machine monitor
Detail of failure
is defective.
q Uses CAN information that was sent from KOMTRAX Plus controller before the occurrence of the
Action of con- error.
Problem on
machine
Related infor-
mation

2. Disconnect connectors V4A, M7 and connect T-adapter.
1
(wire breakage or defective con- Wiring harness between V4A (female) (6) and M7
(female) (9)
Resistance
Wiring harness between V4A (female) (14) and M7
Max. 1 z
(female) (10)
2 Between ground and wiring harness from V4A
(female) (6) to M7 (female) (9)
Resistance
Between ground and wiring harness from V4A
Min. 1 Mz
Hot short circuit in wiring harness Between ground and wiring harness from V4A
3 Max. 1 V
(connection with 24 V circuit) (female) (6) to M7 (female) (9)
Voltage
Max. 1 V
4
(Between CANH and CANL) V4A (female) Resistance
Between (A) and (B) 12012 z
a If no failure is found in above diagnoses for causes 1 to 5, KOMTRAX Plus
6 controller may be defective. (Since this is an internal defect, troubleshoot-
ler
WA1200-6 40-243
Failure code [DBBQMC] Communication Lost (VHMS CAN0)
40-244 WA1200-6
Failure code [DBBRKR] Communication Lost VHMS Controller
Failure code [DBBRKR] Communication Lost VHMS Controller 40-245

Action
Failure code CAN-NET signal communication error (KOMTRAX Plus)
level Failure
E03 DBBRKR
q Machine monitor cannot obtain information from KOMTRAX Plus controller through CAN commu-
Detail of failure
nication circuit.
Action of con-
q Holds information at the time of occurrence of failure.
troller
Problem on q System may not operate properly.
machine q Information from KOMTRAX Plus controller is not displayed.
Related infor-
mation

1 Perform troubleshooting for failure Code [DAFRKR].
WA1200-6 40-245
Failure code [DBBRMC] Communication Lost (VHMS CAN1)
Failure code [DBBRMC] Communication Lost (VHMS CAN1) 40-246

Action
level Failure
E03 DBBRMC
q Communication via CAN signal line between the machine monitor and KOMTRAX Plus controller
Detail of failure
is defective.
q Uses CAN information that was sent from KOMTRAX Plus controller before the occurrence of the
Action of con- error.
Problem on
machine
Related infor-
mation

2. Disconnect connectors V4A, FC06 and connect T-adapter.
1
(wire breakage or defective con- Wiring harness between V4A (female) (4) to FC06
(female) (3)
Resistance
Wiring harness between V4A (female) (12) to FC06
Max. 1 z
(female) (8)
2 Between ground and wiring harness from V4A
Resistance
Min. 1 Mz
Hot short circuit in wiring harness Between ground and wiring harness from V4A
3 Max. 1 V
(connection with 24 V circuit) (female) (4) to FC06 (female) (3)
Voltage
Max. 1 V
4
(Between CANH and CANL) V4A (female) Resistance
a If no failure is found in above diagnoses for causes 1 to 5, KOMTRAX Plus
6 controller may be defective. (Since this is an internal defect, troubleshoot-
ler
40-246 WA1200-6
Failure code [DBBRMC] Communication Lost (VHMS CAN1)
WA1200-6 40-247
Failure code [DD10KX] Verification Mode SW Failure
Failure code [DD10KX] Verification Mode SW Failure 40-248

Action
Failure code Inspection mode switch system error (input signal out of range)
level Failure
E01 DD10KX
Detail of failure Open circuit or ground fault has occurred in the inspection mode switch circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect connectors L03, S31 and connect T-adapter.
Max. 1 z
Open circuit in wiring harness CHK (male) (4)
1 (wire breakage or defective con- Wiring harness between L04 (female) (9) and CHK
Max. 1 z
tact of connector) (male) (2)
Resistance
Max. 1 z
CHK (male) (1)
Max. 1 z
CHK (male) (3)
Min. 1 Mz
CHK (male) (4)
2 Wiring harness between L04 (female) (9) and CHK
(male) (2)
Resistance
Min. 1 Mz
CHK (male) (1)
Min. 1 Mz
CHK (male) (3)
40-248 WA1200-6
Failure code [DD10KX] Verification Mode SW Failure
WA1200-6 40-249
Failure code [DD1ALD] Remote positioner upper side set sw failure
Failure code [DD1ALD] Remote positioner upper side set sw failure 40-250
Action Remote positioner RAISE/LOWER stop position set switches
Failure code
level Failure (RAISE): LOWER stop position set switch error
E01 DD1ALD (Boom bucket & AJSS controller system)
q RAISE stop position cannot be set due to ground fault in remote positioner RAISE stop position set
Detail of failure
switch system (RAISE)
q Cancels setting operation of lift arm RAISE stop position.
q Cancels remote RAISE stop function.
Action of con-
q Turns off lift arm RAISE stop pilot lamp.
troller
to OFF position.
Problem on q Setting of lift arm RAISE stop position for remote positioner is disabled.
machine q Remote positioner RAISE stop function does not work.
q Input (ON/OFF) from remote positioner RAISE/LOWER (RAISE) stop position set switch can be
Related infor-
checked by using monitoring function. (Code: 40913 D-IN-28)
mation

Defective remote positioner Remote positioner
RAISE/LOWER (RAISE) stop S12 (male) RAISE/LOWER stop Resistance
1 position set switches
position set switch
(Internal short circuit) RAISE Max. 1 z
Between (5) and (6)
Between (6) and ground Ladder at any position Min. 1 Mz
2
(female) (13) to S12 (female) (6)
Remote positioner
3 L06 (male) RAISE/LOWER stop Voltage
controller
position set switches
RAISE Max. 1 V
40-250 WA1200-6
Failure code [DD1ALD] Remote positioner upper side set sw failure
WA1200-6 40-251
Failure code [DD1BLD] Remote positioner lower side set sw failure
Failure code [DD1BLD] Remote positioner lower side set sw failure 40-252
Action Remote positioner RAISE/LOWER stop position set switches
Failure code
level Failure (LOWER): LOWER stop position set switch error
E01 DD1BLD (Boom bucket & AJSS controller system)
q LOWER stop position cannot be set due to ground fault in remote positioner RAISE/LOWER
Detail of failure
(RAISE) stop position set switch circuit.
q Cancels setting operation of lift arm LOWER stop position.
q Cancels remote LOWER stop function.
Action of con-
q Turns off lift arm LOWER stop pilot lamp.
troller
to OFF position.
Problem on q Setting of lift arm LOWER stop position for remote positioner is disabled.
machine q Remote positioner LOWER stop function does not work.
q Input (ON/OFF) from remote positioner RAISE/LOWER (LOWER) stop position set switch can be
Related infor-
checked by using monitoring function. (Code: 40913 D-IN-29)
mation

Defective remote positioner Remote positioner
RAISE/LOWER stop position set S12 (male) RAISE/LOWER stop Resistance
1 position set switches
switches
(Internal short circuit) LOWER Max. 1 z
Between (4) and (5)
Between (4) and ground Ladder at any position Min. 1 Mz
2
Remote positioner
3 L06 (male) RAISE/LOWER stop Voltage
controller
position set switches
LOWER Max. 1 V
40-252 WA1200-6
Failure code [DD1BLD] Remote positioner lower side set sw failure
WA1200-6 40-253
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit 40-254
Action
Failure code RPM set ON/OFF switch: ON/OFF signals disagree.
level Failure
E01 DDA7L4
Detail of failure q RPM set does not function because of a hot short circuit in RPM set ON/OFF switch system.
Action of con- q Turns RPM set function OFF.
Problem on
q RPM setting can not be made.
machine
q Input condition (ON/OFF) from RPM set ON/OFF switch (pressed upward) can be checked with
monitoring function (Code: 44200 THROT LOCK A).
Related infor- q Input condition (ON/OFF) from RPM set ON-OFF switch (pressed downward) can be checked with
mation monitoring function (Code: 44201 THROT LOCK B).
q Method of reproducing failure code: Set the starting switch to ON position + Set the RPM set
ON/OFF switch to ON position

S18 (male) RPM set ON/OFF switch Resistance
Defective RPM set ON/OFF ON Min. 1 Mz

1 Between (4) and (5)
OFF Max. 1 z
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (4), (5), (6) and
Ladder at any position Min. 1 Mz
ground
2 Max. 1 V
(contact with 24 V circuit) (female) (13) to S18 (female) (4)
Voltage
Max. 1 V
L02 RPM set ON/OFF switch Voltage

3 Defective transmission controller ON Max. 1 V
OFF 20 to 30 V
ON 20 to 30 V
OFF Max. 1 V
40-254 WA1200-6
Failure code [DDA7L4] Throttle Lock Input signal Short Circuit
WA1200-6 40-255
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short

Circuit 40-256
Action
Failure code RPM set idle-up/down selector switch (idle-down): short circuit
level Failure
E01 DDA8KB
q Idle-up does not function because of ground fault in RPM set idle-up/down selector switch (idle-up)
Detail of failure
system.
Problem on
machine
q Input condition (ON/OFF) from RPM set idle-up/down selector switch can be checked with moni-
Related infor- toring function (Code: 40906 D-IN-13 D-IN-14).
mation q Method of reproducing failure code: Turn starting switch ON, turn RPM set ON/OFF switch ON,
and operate the RPM set idle-up/down selector switch (idle-up)

RPM set idle-up/down
Defective RPM set idle-up/down S19 (male) Resistance
selector switch
1 selector switch
(internal short circuit) At idle-up position Max. 1 z
Between (5) and (6)
At idle-down position Min. 1 Mz
Between (4), (6) and
ground
2
L04 Voltage
3 Defective transmission controller selector switch
At idle-up position Max. 1 V
Between (19) and ground Idle-down position or
7–10 V
NEUTRAL
40-256 WA1200-6
Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit
WA1200-6 40-257
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short

Circuit 40-258
Action
Failure code RPM set idle-up/down selector switch (idle-down): short circuit
level Failure
E01 DDA9KB
q Engine speed cannot be set to optional speed because of ground fault in RPM set idle-up/down
Detail of failure
selector switch system.
Problem on
machine
q Input condition (ON/OFF) from RPM set idle-up/down selector switch can be checked with moni-
Related infor- toring function (Code: 40906 D-IN-13 D-IN-14).
mation q Method of reproducing failure code: Turn starting switch ON, turn RPM set ON/OFF switch ON,
and operate the RPM set idle-up/down selector switch (idle-down)


Defective RPM set idle-up/down S19 (male) Resistance
selector switch
1 selector switch
(internal short circuit) At idle-up position Min. 1 Mz
Between (4) and (5)
At idle-down position Max. 1 z
ground
2

L04 Voltage
3 Defective transmission controller selector switch
Idle-up position or Neu-

7–10 V
Between (29) and ground tral
At idle-down position Max. 1 V
40-258 WA1200-6
Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit
WA1200-6 40-259
Failure code [DDB6L4] Neutral Signal Malfunction
Failure code [DDB6L4] Neutral Signal Malfunction 40-260

Action
Failure code Neutralizer signal system error
level Failure
E03 DDB6L4
Detail of failure Open circuit or ground fault has occurred in neutralizer signal circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Defective parking brake safety 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
relay L59 (male) Resistance
2. Disconnect connectors L03, FC09, HR14 and connect T-adapter.
2 (wire breakage or defective con- Between ground and wiring harness from L03
Min. 1 Mz
tact of connector) (female) (6) to FC09 (female) (3)
Resistance
Min. 1 Mz
2. Disconnect connectors L03, FC09, HR14 and connect T-adapter.
Resistance
Min. 1 Mz
L03(female) Voltage
40-260 WA1200-6
Failure code [DDB6L4] Neutral Signal Malfunction
WA1200-6 40-261
Failure code [DDD7KA] Speed control dial circuit (Low Voltage)
Failure code [DDD7KA] Speed control dial circuit (Low Voltage) 40-262
Action
Failure code Travel speed control dial system error (input signal out of range)
level Failure
E01 DDD7KA
Detail of failure Open circuit or ground fault has occurred in the travel speed sensor circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective travel speed sensor FC16 (male) Resistance
Between (1) and (3) Change frame angle 0.2 – 5 kz
Between (1) and (2) 0 – 5 kz
2. Disconnect connectors L02, L04, FC16 and connect T-adapter.
FC16 (female) (2)
Resistance
Max. 1 z
FC16 (female) (1)
(Contact with ground circuit) Min. 1 Mz
Resistance
(female) (34) to FC16 (female) (1) Min. 1 Mz

(4)–(14) 4.9 – 5.1 V
40-262 WA1200-6
Failure code [DDD7KA] Speed control dial circuit (Low Voltage)
WA1200-6 40-263
Failure code [DDD7KB] Speed control dial circuit (High Voltage)
Failure code [DDD7KB] Speed control dial circuit (High Voltage) 40-264
Action
Failure code Travel speed control dial system error (input signal out of range)
level Failure
E01 DDD7KB
Detail of failure Hot short circuit has occurred in travel speed sensor circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

3. Turn the starting switch to OFF position, then perform troubleshooting..
1 Defective travel speed sensor FC16 (male) Resistance
Between (1) and (3) Change frame angle 0.2 – 5 kz
Voltage
(female) (34) to FC16 (female) (1) Max. 1 V

(4)–(14) 4.9 – 5.1 V
40-264 WA1200-6
Failure code [DDD7KB] Speed control dial circuit (High Voltage)
WA1200-6 40-265
Failure code [DDDBKA] Traction control dial circuit (Low Voltage)
Failure code [DDDBKA] Traction control dial circuit (Low Voltage) 40-26
Action
Failure code Traction adjustment dial: open circuit, ground fault
level Failure
E01 DDDBKA
q Traction adjustment is disabled because of open circuit or ground fault in traction adjustment dial
Detail of failure system
(Traction adjustment dial signal voltage: max. 0.3 V)
q Uses traction adjustment dial value immediately before failure is detected.
Action of con-
troller
Problem on
q Traction adjustment is disabled
machine
q Input (%) from traction adjustment dial can be checked by using monitoring function. (Code: 94000
TRACTION DIAL)
Related infor-
q Input (voltage) from traction adjustment dial can be checked by using monitoring function. (Code:
mation
94001 TRACTION DIAL)

FC15 (male) Dial position Voltage
Defective traction adjustment dial
1 Between (1) and (3) Ladder at any position 4.75 to 5.25V
Ladder at any position 0.5 – 4.5 V
Between (2) and (3) MAX 0.5–1.0 V
MIN 4.0–4.5 V
Open circuit in wiring harness Wiring harness between L02 (female) (3) and
Max. 1 z
2 (wire breakage or defective con- FC15 (female) (2)
tact of connector) Wiring harness between L02 (female) (4) and FC15 Resistance
Max. 1 z
(female) (3)
Max. 1 z
FC15 (female) (1)
2. Disconnect connectors L02, FC15 and connect T-adapter.
3 Min. 1 Mz
(contact with ground circuit) (female) (3) to FC15 (female) (2)
Resistance
(female) (34) to FC15 (female) (1) Min. 1 Mz

L02 Dial position Voltage
Between (3) and ground Ladder at any position 4.75 to 5.25V
40-266 WA1200-6
Failure code [DDDBKA] Traction control dial circuit (Low Voltage)
WA1200-6 40-267
Failure code [DDDBKB] Traction control dial circuit (High Voltage)
Failure code [DDDBKB] Traction control dial circuit (High Voltage) 40-268
Action
Failure code Traction adjustment dial: hot short circuit
level Failure
E01 DDDBKB
q Traction adjustment is disabled because of open circuit in traction adjustment dial system.
Detail of failure
(Traction adjustment dial signal voltage: max. 0.3 V)
q Uses traction adjustment dial value immediately before failure is detected.
Action of con-
troller
Problem on
q Traction adjustment is disabled
machine
q Input (%) from traction adjustment dial can be checked by using monitoring function. (Code: 94000
TRACTION DIAL)
Related infor-
q Input (voltage) from traction adjustment dial can be checked by using monitoring function. (Code:
mation
94001 TRACTION DIAL)

FC15 (male) Dial position Voltage
Defective traction adjustment dial
1 Between (1) and (3) Ladder at any position 4.75 to 5.25V
Ladder at any position 0.5 – 4.5 V
Between (2) and (3) MAX 0.5–1.0 V
MIN 4.0–4.5 V
2 Wiring harness between L02 (female) (3) and
(contact with +5 V circuit) Max. 1 V
FC15 (female) (2)
Voltage
Wiring harness between L02 (female) (4) and FC15
Max. 1 V
(female) (3)
L02 Dial position Voltage
Between (3) and ground Ladder at any position 4.75 to 5.25V
40-268 WA1200-6
Failure code [DDDBKB] Traction control dial circuit (High Voltage)
WA1200-6 40-269
Failure code [DDE5MA] Emergency steering signal Failure
Failure code [DDE5MA] Emergency steering signal Failure 40-270

Action
Failure code Emergency steering drive switch: malfunction
level Failure
E01 DDE5MA
q When the engine stops, the steering pump pressure is detected because of the ground fault in the
Detail of failure
emergency steering drive switch system.
q None in particular
Action of con-
troller
to OFF position.
Problem on
q The emergency steering operates.
machine
q Input condition (ON/OFF) from emergency steering motor can be checked with monitoring function
Related infor-
(Code: 40903 D-IN-30).
mation

2. Disconnect connectors R11, R12 and connect T-adapter.
q Relieve the steering circuit
Steering circuit
Defective emergency steering R11, R12 (male) Resistance
relief pressure
1 drive switch
(internal defect) When oil pressure is
Min. 1 Mz
abnormal (low)
Between (1) and (2)
When oil pressure is nor-
Max. 1 z
mal
ground
2. Disconnect connectors FC04, R12, R11 and connect T-adapter.
2
(contact with ground circuit) Between ground and wiring harness from FC04
(female) (3) to R12 (female) and to R11 female (11), Resistance Min. 1 Mz
(1)
q Relieve the steering circuit
Steering circuit
3 Defective machine monitor FC04 (female) Voltage
relief pressure
When oil pressure is
20 to 30 V
abnormal (low)
When oil pressure is nor-
Max. 1 V
mal
40-270 WA1200-6
Failure code [DDE5MA] Emergency steering signal Failure
WA1200-6 40-271
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection 40-272

Action AJSS FNR seesaw switch system error (input signal out of
Failure code
level Failure range)
E03 DDK4KA (Transmission controller system)
Detail of failure Open circuit or ground fault has occurred in AJSS FNR seesaw switch circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective FNR seesaw switch 3. Turn starting switch to ON position and perform troubleshooting.
Between S31 (female) (2), (3), (4) and ground Resistance Min. 1 Mz
Open circuit in wiring harness Wiring harness between L03 (female) (16) and S31
Max. 1 z
2 (wire breakage or defective con- (female) (4)
tact of connector) Wiring harness between L03 (female) (26) and S31
Resistance Max. 1 z
(female) (3)
Wiring harness between L03 (female) (36) and S31
Max. 1 z
(female) (2)
Ground fault in wiring harness Min. 1 Mz
3 (female) (16) to S31 (female) (4)
Min. 1 Mz
Between (16), (26), (36) and ground Min. 1 Mz
40-272 WA1200-6
Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection
WA1200-6 40-273
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit 40-274
Action AJSS FNR seesaw switch system error (input signal out of
Failure code
E03 DDK4KB (Transmission controller system)
Detail of failure Hot short circuit has occurred in AJSS FNR seesaw switch circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective FNR seesaw switch 3. Turn starting switch to ON position and perform troubleshooting.
Between S31 (female) (2), (3), (4) and ground Resistance Min. 1 Mz
Max. 1 V
2 (Defective contact with 24 V cir- (female) (5) to S31 (female) (5)
cuit) Between ground and wiring harness from L03
Voltage Max. 1 V
Max. 1 V
Between (16), (26), (36) and ground Min. 1 Mz
40-274 WA1200-6
Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit
WA1200-6 40-275
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Discon-

Action
Failure code AJSS upshift system error (input signal out of range)
level Failure
E01 DDK5L4
Detail of failure Open circuit, ground fault, or hot short circuit has occurred in AJSS upshift circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective AJSS upshift 3. Turn starting switch to ON position and perform troubleshooting.
Between S31 (female) (5), (15), (25), (35) and
ground
Max. 1 z
2 (wire breakage or defective con- Wiring harness between L03 (female) (15) and S31
Max. 1 z
Resistance
Max. 1 z
(female) (7)
Max. 1 z
(female) (8)
Min. 1 Mz
Resistance
Min. 1 Mz
Min. 1 Mz
Max. 1 V
Voltage
Max. 1 V
Max. 1 V
40-276 WA1200-6
Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)

L03 (female) Resistance
Between (5), (15), (25), (35) and
Min. 1 Mz
ground
WA1200-6 40-277
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect
Failure code [DDP5KA] Steering lock detector pressure switch signal

circuit Disconnect 40-278
Action Lock detection pressure switch for steering lock lever: open cir-
Failure code
level Failure cuit, hot short circuit
E01 DDP5KA (Transmission controller system)
q Steering lock lever lock signal cannot be detected due to open circuit in lock detection pressure
Detail of failure
switch for steering lock lever.
Action of con- q None in particular
Problem on
q Even if steering lock lever is set to LOCK position, steering can be operated.
machine
q The input (ON/OFF) from the lock detection pressure switch for the steering lock lever can be
Related infor- checked by using the monitoring function (Code: 40908 D-IN-31).
mation q Method of reproducing failure code: Set the starting switch to ON position + Lock the steering lock
lever

2. Disconnect connector STL and connect T-adapter.
Defective lock detection pressure
1 switch for steering lock lever Steering lock
STL (male) Resistance
(Internal open circuit) lever
LOCK Min. 1 Mz
Between (1) and (2)
Free Max. 1 z
Open circuit in wiring harness 2. Disconnect connectors L03, STL and connect T-adapter.
tact of connector) Wiring harness between L03 (female) (38) and STL
Resistance Max. 1 z
(female) (1)
2. Disconnect connectors L03, STL and connect T-adapter.
(contact with circuit)
Voltage Max. 1 V
(female) (38) to STL (female) (1)
4 Defective transmission controller L03 Steering lock lever Voltage
LOCK 8–10 V
Free Max. 1 V
40-278 WA1200-6
Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect
WA1200-6 40-279
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit 40-280
Action Transmission cut-off point set switch system error (open or short
Failure code
level Failure circuit)
E01 DDT4LD (Transmission controller system)
Detail of failure Ground fault has occurred in the cut-off point set switch circuit
Action of con- q Cut-off point set switch: OFF
Problem on
machine
Related infor-
mation
monitor

Defective transmission cut-off 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
point set switch S21 (male) Resistance
Between (5) and (6) 15 – Min. 25 z

2 Min. 1 Mz
(contact with ground circuit) (female) (20) to S21 (female) (1)
Resistance
Min. 1 Mz
3 Defective transmission controller L04 (female) Voltage
Between (20) and ground Max. 1 V
40-280 WA1200-6
Failure code [DDT4LD] T/M Cut Off set switch signal short circuit
WA1200-6 40-281
Failure code [DDW9LD] Kickdown Switch Short Circuit
Failure code [DDW9LD] Kickdown Switch Short Circuit 40-282

Action
Failure code Kick-down switch: switch is kept pressed for long time
level Failure
E01 DDW9LD
Detail of failure q Due to ground fault in kickdown switch system, the kickdown signal is not turned off.
q Turns the kick-down ON when a grounding fault is detected, then do not control the kick-down any
Action of con-
more.
troller
Problem on
q When ground fault occurs, kick-down occurs once
machine
q The input signal status (ON/OFF) from the kick-down switch can be checked by using the monitor-
Related infor-
ing function (Code: 40906 D-IN-10).
mation

Kick-down
S07 (male) Resistance
Defective kickdown switch switch
1
(Internal short circuit)
ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
ground
2
Kick-down
3 Defective transmission controller L04 Voltage
switch
ON Max. 1 V
OFF 8–10 V
40-282 WA1200-6
Failure code [DDW9LD] Kickdown Switch Short Circuit
WA1200-6 40-283
Failure code [DGE5KX] Ambient air temp Sensor Failure
Failure code [DGE5KX] Ambient air temp Sensor Failure 40-284

Action
Failure code Ambient temperature sensor system error
level Failure
E01 DGE5KX
Detail of failure An error has occurred in the ambient temperature sensor circuit (input signal out of range)
Action of con-
troller
Problem on
Pm Clinic display becomes abnormal
machine
Related infor-
mation

2. Disconnect connector PH1 and connect T-adapter.
Defective ambient temperature 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
sensor PH1 (male) Ambient temperature Resistance
Normal temperature
Between (1) and (2) Approx. 12 kz
(25 °C)
Open circuit in wiring harness 2. Disconnect connectors from V2A to PH1 in turn, and connect T-adapter.
tact of connector) Wiring harness between V2A (female) (10) and
Resistance Max. 1 z
PH1 (female) (1)
2. Disconnect connectors from V2A to PH1 in turn, and connect T-adapter.
3
(female) (10) to PH1 (female) (1)
Voltage Max 1 V
(female) (10) to PH1 (female) (1)
2. Disconnect connectors from V2A to PH1 in turn, and connect T-adapter.
5 V2A Ambient temperature Resistance
ler
0 °C Approx. 4 kz
Between (10) and (13)
25 °C Approx. 12 kz
40-284 WA1200-6
Failure code [DGE5KX] Ambient air temp Sensor Failure
WA1200-6 40-285
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect
Failure code [DGF1KA] Transmission Oil Temperature sensor signal

Disconnect 40-286
Action
Failure code Transmission oil temperature sensor: Open circuit
level Failure
E01 DGF1KA
q Signal voltage from transmission oil temperature sensor is higher than normal range due to open
circuit in transmission oil temperature sensor signal circuit.
Detail of failure
(Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max. 15 °C) and transmission
oil temperature sensor signal voltage: Min. 3.7 V (55 °C)
Action of con- q Determines that transmission oil temperature is unusually low.
Problem on
q Gear shift shock may occur
machine
q Input (temperature) from transmission oil temperature sensor can be checked by using monitoring
function. (Code: 93600 T/M OIL TEMP)
Related infor-
q Input (voltage) from transmission oil temperature sensor can be checked by using monitoring func-
mation
tion. (Code: 93601 T/M OIL TEMP)

2. Disconnect connectors T19, T25 and connect T-adapter.
Defective transmission oil temper- Between T19 and T25 Transmission oil
1 ature sensor (internal open or Resistance
(male) temperature
short circuit)
25 °C (normal tempera-
35–50 kz
Between (1) and (2) ture)
100 °C 3.1–4.5 kz
2. Disconnect connectors L02, T19, T25 and connect T-adapter.
2 (wire breakage or defective con- Wiring harness between L02 (female) (9) and T19
Resistance Max. 1 z
Wiring harness between T25 (female) (1) and L02
Resistance Max. 1 z
(female) (20)
Transmission oil
3 Defective transmission controller L02 (female) Resistance
temperature
(9)–(10) 35–50 kz
ture)
(20)–(10)
100 °C 3.1–4.5 kz
40-286 WA1200-6
Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect
WA1200-6 40-287
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature

sensor Short Circuit 40-28
Action
Failure code Transmission oil temperature sensor: short circuit
level Failure
E01 DGF1KB
q Signal voltage from transmission oil temperature sensor is lower than normal range due to ground
Detail of failure fault in transmission oil temperature sensor signal circuit.
(Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150 °C))
Action of con- q Determines that transmission oil temperature is unusually high.
Problem on
Gear shift shock may occur
machine
q Input (temperature) from transmission oil temperature sensor can be checked by using monitoring
function. (Code: 93600 T/M OIL TEMP)
Related infor-
q Input (voltage) from transmission oil temperature sensor can be checked by using monitoring func-
mation
tion. (Code: 93601 T/M OIL TEMP)

2. Disconnect connectors T19, T25 and connect T-adapter.
Defective transmission oil temper- Transmission oil
1 T19, T25 (male) Resistance
ature sensor (internal short circuit) temperature
35–50 kz
100 °C 3.1–4.5 kz
2. Disconnect connectors L02, T19, T25 and connect T-adapter.
Resistance
Min. 1 Mz
2. Disconnect connectors L02, T19, T25.
3. Insert T-adapter
Hot short circuit in wiring harness 4. Turn starting switch to ON position.
3
(contact with power supply circuit) Between ground and wiring harness from L02
Max. 1 V
Voltage
Max. 1 V
Transmission oil
4 Defective transmission controller L02 (female) Resistance
temperature
35–50 kz
100 °C 3.1–4.5 kz
40-288 WA1200-6
Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit
WA1200-6 40-289
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure

(For Check) 40-290
WA1200-6
Action
Failure code Transmission oil temperature sensor: failure (for detection)
level Failure
E01 DGF1KX
q When the voltage of the signal circuit of the transmission oil temperature sensor is below 0.97 V
(above 150 °C), or only transmission oil temperature is low (transmission oil temperature sensor sig-
Detail of failure
nal circuit voltage is above 4.56 V (below 15 °C) and torque converter oil temperature sensor voltage
is normal (below 3.7 V (above 55 °C)).
Action of con-
q Controls clutch oil pressure while recognizing oil temperature as fixed high temperature
troller
Problem on
q Gear shift shocks will be larger
machine
q This can be checked by using monitoring function (Code: 93600 ( °C), 93601 (V)).
Related infor- q After confirming that normal condition is recovered after repair work, perform the initial learning of
mation the transmission controller, referring to Testing and adjusting, "Setting and adjusting of each equip-
ment".

2. Disconnect connector T19.
Transmission oil temperature 3. Connect T-adapter
1
Defective sensor Oil temperature: 25 °C 37–50 kz
Between T19 (male) (1)
Resistance
and (2) Oil temperature: 100 °C 3.5–4.0 kz
2. Disconnect connectors L02, T19.
Open circuit in wiring harness 3. Connect T-adapter
T19 (female) (2)
Resistance
Wiring harness between L02 (female) (9) and T19
Max. 1 z
(female) (1)
Ground fault in wiring harness 3. Connect T-adapter
3
Hot short circuit in wiring harness 3. Insert T-adapter
4
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Max 5 V
3. Insert T-adapter
5 Defective transmission controller 4. Turn starting switch to ON position.
Oil temperature: 25 °C 37–50 kz
Between L02 (female)
Resistance
(9) and (10) Oil temperature: 100 °C 3.5–4.0 kz
40-290 WA1200-6
Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)
WA1200-6 40-291
Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure
Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure 40-292
Action
Failure code Hydraulic oil temperature sensor system error
level Failure
E01 DGH2KX
Detail of failure An error has occurred in the hydraulic oil temperature sensor circuit (input signal out of range)
Action of con-
troller
Problem on
Wrong alarm output
machine
Related infor-
mation

Defective hydraulic oil tempera- 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
ture sensor HS1 (male) Resistance Resistance
Between (1) and (2) 0.2–5 kz Approx. 37 – 50 kz
2. Disconnect connectors FC05, HSI and connect T-adapter.
(female) (7) to HSI (female) (1)
FC05 (female) Voltage
40-292 WA1200-6
Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure
WA1200-6 40-293
Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection
Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection 40-294
Action
Failure code Rear brake oil temperature sensor: Open circuit
level Failure
E01 DGR2KA
q Signal voltage from rear brake oil temperature sensor is higher than normal range due to open or
Detail of failure hot short circuit in rear brake oil temperature sensor signal system
(Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150 °C))
q Takes it that the rear brake oil temperature is unusually low.
Action of con-
troller
Problem on
–
machine
q Input (temperature) from rear brake oil temperature sensor can be checked by using monitoring
function. (Code: 30202 R BRAKE OIL)
Related infor-
q Input (voltage) from rear brake oil temperature sensor can be checked by using monitoring func-
mation
tion. (Code: 30205 R BRAKE OIL)

Defective rear brake oil tempera-
1 HS6 (male) Hydraulic oil temperature Resistance
ture sensor (internal open circuit)
35–50 kz
100 °C 3.1–4.5 kz
2. Disconnect connectors FC05, HS6 and connect T-adapter.
HS6 (female) (1)
Resistance
Wiring harness between HS6 (female) (2) and
Max. 1 z
ground
2. Disconnect connectors L02, T19, T25.
3. Insert T-adapter
Hot short circuit in wiring harness 4. Turn starting switch to ON position.
3
(contact with power supply circuit) Between ground and wiring harness from FC05
Max. 1 V
Voltage
Max. 1 V
4 Defective machine monitor FC05 (female) Engine oil temperature Resistance
35–50 kz
Between (8) and ground ture)
100 °C 3.1–4.5 kz
40-294 WA1200-6
Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection
WA1200-6 40-295
Failure code [DGR2KX] Brake oil temp. sensor circuit failure
Failure code [DGR2KX] Brake oil temp. sensor circuit failure 40-296
Action Rear brake oil temperature sensor: Input signal is out of normal
Failure code
level Failure range
E01 DGR2KX (Machine monitor system)
q Signal voltage from rear brake oil temperature sensor is lower than normal range due to ground
Detail of failure fault in rear brake oil temperature sensor signal circuit.
Action of con- q Takes it that the rear brake oil temperature is unusually high.
Problem on
–
machine
q Input (temperature) from rear brake oil temperature sensor can be checked by using monitoring
function. (Code: 30202 R BRAKE OIL)
Related infor-
q Input (voltage) from rear brake oil temperature sensor can be checked by using monitoring func-
mation
tion. (Code: 30205 R BRAKE OIL)

Defective rear brake oil tempera-
1 HS6 (male) Hydraulic oil temperature Resistance
ture sensor (internal short circuit)
35–50 kz
100 °C 3.1–4.5 kz
2. Disconnect connectors FC05, HS6 and connect T-adapter.
2
3 Defective machine monitor FC05 (female) Engine oil temperature Resistance
35–50 kz
100 °C 3.1–4.5 kz
40-296 WA1200-6
Failure code [DGR2KX] Brake oil temp. sensor circuit failure
WA1200-6 40-297
Failure code [DGT1KX] T/C oil temp. sensor circuit failure
Failure code [DGT1KX] T/C oil temp. sensor circuit failure 40-298
Action
Failure code Torque converter oil temperature sensor system error
level Failure
E01 DGT1KX
Detail of failure An error occurs in torque converter oil temperature sensor circuit (input signal out of range).
Action of con-
troller
Problem on
Wrong alarm output.
machine
Related infor-
mation

Defective torque converter oil tem- 3. Turn starting switch to OFF position, then perform troubleshooting.
1
perature sensor T24 Engine oil temperature Resistance
Normal temperature
Between (1) and (2) Approx. 40 kz
(25 °C)
2. Disconnect connectors from FC05 to T24 in turn, and connect T-adapter.
2 3. Turn starting switch to OFF position, then perform troubleshooting.
Between ground and wiring harness between FC05
(female) (2) and T24 (female) (1)
40-298 WA1200-6
Failure code [DGT1KX] T/C oil temp. sensor circuit failure
WA1200-6 40-299
Failure code [DH20KX] Torque converter pressure sensor circuit
Failure code [DH20KX] Torque converter pressure sensor circuit 40-30

Action
Failure code Torque converter outlet pressure sensor system error
level Failure
E01 DH20KX
Detail of failure An error has occurred in the torque converter outlet pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on
machine Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})
Related infor- If failure code DHT3KX, DHT9KX, or DHT5KX is issued at the same time, there is an open circuit,
mation defective contact, or ground fault in the wiring harness between V1 (female) (2) and JT2 (female) (1).

2. Disconnect sensor MT3 and replace with a normally operating sensor.
Defective torque converter outlet
pressure sensor (MT3)
Check if normal condition is recovered when torque converter outlet pressure
sensor (MT3) is replaced with a normally operating sensor
2. Disconnect connectors JT4 and JT5 and connect T-adapter.
Defective joint connector (JT4 or 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
JT5) Between JT4 (male) (4) and (5) Max. 1 z
Resistance
Between JT5 (male) (2) and (3) Max. 1 z
2. Disconnect connectors from V1 to MT3 and from V2A to MT3 in turn, and
connect T-adapter.
3 (wire breakage or defective con- Wiring harness between V1 (female) (2) and MT3 Max. 1 z
tact of connector) (female) (B)
Wiring harness between V2A (female) (5) and MT3
Resistance Max. 1 z
(female) (C)
Wiring harness between MT3 (female) (1) and
Max. 1 z
ground
connect T-adapter.
4
(Contact with ground circuit) Between ground and wiring harness from V1
Min. 1 Mz
(female) (2) to MT3 (female) (B)
Resistance
Min. 1 Mz
(female) (5) to MT3 (female) (C)
2. Disconnect connectors from V1 to MT3 in turn, and connect T-adapter.
5
ler V1 (female), MT3 (female) Resistance
Between V1 (2), MT3 (B) and ground Min. 1 Mz
40-300 WA1200-6
Failure code [DH20KX] Torque converter pressure sensor circuit
WA1200-6 40-301
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short

Circuit) 40-302
Action
Failure code Work equipment relief pressure sensor system error
level Failure
E01 DH21KA
Detail of failure An error has occurred in the work equipment relief pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on
q If failure code DHU3KX, DHU2KX, DHT8KX, or DHT4KX is issued at the same time, there is an
Related infor- open circuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and
mation JR14 (female) (1).
q Work equipment relief pressure sensor voltage between HS2 (3) and (1): 0.7 - 5.3 V

2. Replace sensor HS2 with a normally operating oil pressure sensor.
Defective work equipment relief
pressure sensor (HS2)
Check if normal condition is recovered when work equipment relief pressure
sensor (HS2) is replaced with a normally operating oil pressure sensor
2. Disconnect connectors to L05 in turn
Connect T-adapter to each connector to HS2.
Wiring harness between L05 (female) (22) and HS2
2 (wire breakage or defective con- Max. 1 z
(female) (B)
tact of connector)
Wiring harness between L05 (female) (2) and HS2
Resistance Max. 1 z
(female) (C)
Wiring harness between HS2 (female) (A) and
Max. 1 z
ground
2. Disconnect connectors between L05 and HS2 in turn and connect
T-adapter.
3
(Contact with ground circuit) Between ground and wiring harness from L05
Min. 1 Mz
(female) (22) to HS2 (female) (B)
Resistance
Min. 1 Mz
(female) (2) to HS2 (female) (C)
2. Disconnect connectors L05, HS2 and connect T-adapter.
4
controller L05 (female), HS2 (female) Resistance
Between L05 (22), HS2 (B) and
Min. 1 Mz
ground
40-302 WA1200-6
Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)
WA1200-6 40-303
Failure code [DH21KB] Loader pump oil press sensor hot short
Failure code [DH21KB] Loader pump oil press sensor hot short 40-304
Action
Failure code Work equipment relief pressure sensor system error
level Failure
E01 DH21KB
Detail of failure An error occurs in work equipment relief pressure sensor circuit (input signal out of range).
Action of con-
troller
Problem on
q If failure codes DHU3KX, DHU2KX, DHT8KX, and DHT4KX occur at the same time, there is open
Related infor- circuit, defective contact, or ground fault in wiring harness between V1 (female) (2) and JR14 (fe-
mation male) (1).
q Work equipment relief pressure sensor voltage between HS2 (3) and (1): 0.7 to 5.3 V

2. Replace sensor HS2 with a normally operating oil pressure sensor.
Defective work equipment relief
pressure sensor (HS2)
Check if normal condition is recovered when work equipment relief pressure
sensor (HS2) is replaced with normally operating oil pressure sensor
2. Disconnect connectors between L05 and HS2 in turn and connect
Hot short circuit in wiring harness T-adapter.
2
(contact with power supply circuit) 3. Turn starting switch to ON position and perform troubleshooting.
Between ground and wiring harness between L05
Voltage Max. 1 V
(female) (2) and HS2 (female) (C)
2. Disconnect connectors L05, HS2 and connect T-adapter.
3
controller L05 (female), HS2 (female) Resistance
Between L05 (22), HS2 (B) and
Min. 1 Mz
ground
40-304 WA1200-6
Failure code [DH21KB] Loader pump oil press sensor hot short
WA1200-6 40-305
Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)
Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)40-306

Action
Failure code Boom bottom pressure sensor system error
level Failure
E01 DHPCKA
Detail of failure An error has occurred in the boom bottom pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on
Load meter reading is constantly 0 ton
machine
Related infor- Boom bottom pressure sensor voltage
mation q Between F06 (C) and (A): 0.7 - 5.3 V

2. Disconnect T3 (1st solenoid) and connect T-adapter.
Defective boom bottom pressure
sensor (F06)
Check if "DHPCKA" is displayed when wiring harness is replaced with that for
boom head pressure sensor (F14)
2. Connect T-adapter to connector L04 and each connector to be discon-
2 Defective joint connector (JF4) nected to T3 in turn.
Between JF4 (male) (1) and (7) Resistance Max. 1 z
2. Disconnect connectors from L04 to T3 in turn and connect T-adapter.
3 (wire breakage or defective con- Wiring harness between L05 (female) (14) and F06
(female) (C)
Resistance
Wiring harness between F06 (female) (B) and FC01
Max. 1 z
(female) (16)
(female) (14) to F06 (female) (C)
5 q Between F06 (female) (B) and ground
controller
Between (14) and ground Max. 1 z
40-306 WA1200-6
Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)
WA1200-6 40-307
Failure code [DHPCKX] Boom bottom press. sensor circuit failure
Failure code [DHPCKX] Boom bottom press. sensor circuit failure 40-308
Action
level Failure
E01 DHPCKX
Action of con-
troller
Problem on
machine

2. Replace wiring harness for pressure sensor F06 with wiring harness for
Defective boom bottom pressure pressure sensor F14
1
sensor (F06) 3. Turn starting switch to ON position and perform troubleshooting.
Check if "DHPCKC" is displayed when wiring harness is replaced with that for
2. Disconnect joint connector JF4 and connect T-adapter.
2 Defective joint connector (JF4) 3. Turn the starting switch to OFF position, then perform troubleshooting.
2. Disconnect connector FC05 and connectors from FC01 to F06 in turn, and
connect T-adapter.
Wiring harness between FC05 (female) (9) and F06
(female) (C)
Resistance
Max. 1 z
(female) (16)
2. Disconnect connectors between FC05 and F06 in turn, and connect
4
5 Defective monitor panel controller q Between F06 (female) (B) and ground
40-308 WA1200-6
Failure code [DHPCKX] Boom bottom press. sensor circuit failure
WA1200-6 40-309
Failure code [DHPCKY] Boom bottom press. hot short
Failure code [DHPCKY] Boom bottom press. hot short 40-310

Action
level Failure
E01 DHPCKY
Action of con-
troller
Problem on
machine

2. Replace wiring harness for pressure sensor F06 with wiring harness for
Defective boom bottom pressure pressure sensor F14
1
sensor (F06) 3. Turn starting switch to ON position and perform troubleshooting.
Check if "DHPCKY" is displayed when wiring harness is replaced with that for
3
Voltage Max. 1 V
40-310 WA1200-6
Failure code [DHPCKY] Boom bottom press. hot short
WA1200-6 40-311
Failure code [DHPDKX] Boom head press. sensor circuit failure
Failure code [DHPDKX] Boom head press. sensor circuit failure 40-312
Action
Failure code Boom head pressure sensor system error
level Failure
E01 DHPDKX
Detail of failure An error has occurred in the boom head pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on Variation in accuracy will be large due to lever operation (back pressure cannot be corrected by boom
machine head pressure)
Related infor- Boom head pressure sensor voltage
mation q Between F14 (3) and (1): 0.7 - 5.3 V

Defective boom head pressure and perform troubleshooting.
1
sensor (F14) Check if "DHPDKX" is displayed when wiring harness is replaced with that for
boom bottom pressure sensor (F14)
2. Disconnect connectors from FC05 to F14 and connectors from FC01 to F14
in turn, and connect T-adapter.
Wiring harness between FC05 (female) (4) and F14
(female) (C)
Resistance
Max. 1 z
(female) (16)
4
40-312 WA1200-6
Failure code [DHPDKX] Boom head press. sensor circuit failure
WA1200-6 40-313
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect 40-314
Action
Failure code L.H. brake pressure sensor: Out of input signal range
level Failure
E01 DHT1KX
q Due to ground fault in left brake pressure sensor signal system, the left brake pressure signal level
Detail of failure is lower than normal range
q Judged that left brake pressure is zero
Action of con-
troller
Problem on
–
machine
Related infor-
mation

Defective left brake pressure sen- 3. Turn the starting switch to OFF position, then perform troubleshooting.
1 sor Wiring harness between L02 (female) (2) and L12 (female) (C)
Wiring harness between L02 (female) (16) and L12 (female) (B)
Wiring harness between L02 (female) (4) and L12 (female) (A)
2 Min. 1 Mz
(contact with ground circuit) (female) (2) to L12 (female) (C)
Resistance
(female) (16) to L12 (female) (B) Min. 1 Mz

40-314 WA1200-6
Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect
WA1200-6 40-315
Failure code [DHT2L6] T/M oil filter sensor circuit failure
Failure code [DHT2L6] T/M oil filter sensor circuit failure 40-316
Action
Failure code Transmission oil filter clogging sensor: signal disagrees with run
level Failure
and stop of engine (machine monitor system)
E01 DHT2L6
q Signal voltage from transmission oil filter clogging sensor disagrees with normal run and stop of
Detail of failure
engine due to failure in transmission oil filter clogging sensor signal circuit.
Action of con-
troller
Problem on
q Transmission oil filter clogging caution lamp does not light up.
machine
q Input (ON/OFF) from transmission oil filter clogging sensor can be checked by using monitoring
Related infor-
function. (Code: 40903 D-IN-24)
mation
q Method of reproducing failure code: Start the engine + Run the engine at full speed

2. Disconnect connectors FC03, FC04, R01, R02 and connect T-adapter.
Defective transmission oil filter
1 clogging sensor Transmission oil
R01, R02 (male) Resistance
tor (internal open or short circuit) filter
Normal Max. 1 z
Between (1) and (2)
Clogging Min. 1 Mz
2 (wire breakage or defective con- Wiring harness between FC03 (female) (5) and R02
Max. 1 z
Resistance
Max. 1 z
(female) (1)
Ground fault in wiring harness Between ground and wiring harness from FC03
3 Min. 1 Mz
(contact with ground circuit) (female) (5) to R02 (female) (1)
Resistance
Min. 1 Mz
(female) (5) to R01 (female) (1)
Hot short circuit in wiring harness Between ground and wiring harness from FC03
4 Max. 1 V
(contact with 24 V circuit) (female) (5) to R02 (female) (1)
Voltage
(female) (5) to R01 (female) (1) Max. 1 V

2. Disconnect connectors FC03, FC04 and connect T-adapter.
FC03 (female) Transmission oil
5 Defective machine monitor Resistance
FC04 (female) filter inlet pressure
Normal Max. 1 z
Clogging Min. 1 Mz
40-316 WA1200-6
Failure code [DHT2L6] T/M oil filter sensor circuit failure
WA1200-6 40-317
Failure code [DHT3KX] Transmission main pressure sensor circuit
Failure code [DHT3KX] Transmission main pressure sensor circuit 40-318

Action
Failure code Transmission main pressure sensor system error
level Failure
E01 DHT3KX
Detail of failure An error has occurred in the transmission main pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on
Related infor- If failure code DH20KX, DHT9KX, or DHT5KX is issued at the same time, there is an open circuit,

Defective transmission main relief 3. Turn starting switch to ON position and perform troubleshooting.
1
Check if normal condition is recovered when transmission main relief pressure
2. Disconnect connectors JM4 and JM5 and connect T-adapter.
Defective joint connector (JM4 or 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
JM5) Between JM4 (male) (3) and (5) Max. 1 z
Resistance
Between JM5 (male) (1) and (2) Max. 1 z
connect T-adapter.
Wiring harness between V1 (female) (2) and MT2
(female) (2)
tact of connector)
Wiring harness between V2A (female) (6) and MT2
Resistance Max. 1 z
(female) (C)
Wiring harness between MT2 (female) (1) and
Max. 1 z
ground
2. Disconnect connectors from V1 to MT2 in turn, and connect T-adapter.
4 Between ground and wiring harness from V1
Resistance
Min. 1 Mz
2. Disconnect connectors V1 and MT2 and connect T-adapter.
5
ler V1 (female), MT2 (female) Resistance
40-318 WA1200-6
Failure code [DHT3KX] Transmission main pressure sensor circuit
WA1200-6 40-319
Failure code [DHT4KX] Main PPC oil pressure sensor circuit
Failure code [DHT4KX] Main PPC oil pressure sensor circuit 40-320
Action
Failure code Main PPC oil pressure sensor system error
level Failure
E01 DHT4KX
Detail of failure An error has occurred in the main PPC oil pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on
machine Pm Clinic display: constantly detects minimum pressure (0 MPa {0 kg/cm2})
If failure code DHU3KX, DH24KX, DHU2KX, or DHT8KX is issued at the same time, there is an open
Related infor-
circuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14
mation
(female) (1).

2. Disconnect sensor HS4 and replace with a normally operating sensor.
Defective PPC oil pressure sensor
(HS4)
Check if normal condition is recovered when PPC oil pressure sensor (HS4) is
replaced with a normally operating oil pressure sensor
2. Disconnect connectors JR13 and JR14 and connect T-adapter.
Defective joint connector (JL2, 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
JR7, or JR14) Between JR13 (male) (1) and (6) Max. 1 z
Resistance
Between JR14 (male) (1) and (2) Max. 1 z
2. Disconnect connectors from V1 to HS4 and from V2A to HS4 in turn, and
connect T-adapter.
Wiring harness between V1 (female) (2) and HS4
(female) (B)
tact of connector)
Wiring harness between V2A (female) (1) and HS4
Resistance Max. 1 z
(female) (C)
Max. 1 z
ground
connect T-adapter.
Resistance
(female) (1) to HS4 (female) (C) Min. 1 Mz

2. Disconnect connectors V1 and HS4 and connect T-adapter.
V1 (female), HS4 (female) Resistance
Defective KOMTRAX Plus control- Between V1 (2), HS4 (B) and ground Min. 1 Mz
5
ler 1. Prepare with starting switch at OFF position.
V2A Voltage
Between (1) and (12) 0.7 – 5.3 V
40-320 WA1200-6
Failure code [DHT4KX] Main PPC oil pressure sensor circuit
WA1200-6 40-321
Failure code [DHT5KX] Torque converter intake pressure sensor circuit
Failure code [DHT5KX] Torque converter intake pressure sensor circuit40-32

Action
Failure code Torque converter inlet oil pressure sensor system error
level Failure
E01 DHT5KX
An error has occurred in the torque converter inlet oil pressure sensor circuit (input signal out of
Detail of failure
range)
Action of con-
troller
Problem on
Related infor- If failure code DHT3KX, DH20KX, or DHT9KX is issued at the same time, there is an open circuit,

Defective torque converter inlet 3. Turn starting switch to ON position and perform troubleshooting.
1
Check if normal condition is recovered when torque converter inlet pressure
2. Disconnect connectors JT4 and JT5 and connect T-adapter.
Defective joint connector (JT4 or 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
JT5) Between JT4 (male) (2) and (6) Max. 1 z
Resistance
Between JT5 (male) (1) and (4) Max. 1 z
2. Disconnect connectors from V1 to MT4 and from V2B to MT4 in turn, and
connect T-adapter.
Wiring harness between V1 (female) (2) and MT4
(female) (B)
tact of connector)
Resistance Max. 1 z
MT4 (female) (C)
Wiring harness between MT4 (female) (A) and
Max. 1 z
ground
2. Disconnect connectors from V1 to MT4 and from V2B to MT4 in turn, and
connect T-adapter.
Resistance
(female) (10) to MT4 (female) (C) Min. 1 Mz
40-322 WA1200-6
Failure code [DHT5KX] Torque converter intake pressure sensor circuit

V1 (female), MT4 (female) Resistance
Defective KOMTRAX Plus control- Between V1 (2), MT4 (B) and ground Min. 1 Mz
5
V2B Voltage
Between (10) and (12) 0.7 – 5.3 V
WA1200-6 40-323
Failure code [DHT8KX] Steering Oil Press. Sensor Failure
Failure code [DHT8KX] Steering Oil Press. Sensor Failure 40-324

Action
Failure code Steering oil pressure sensor system error
level Failure
E01 DHT8KX
Detail of failure An error has occurred in the steering oil pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on
If failure code DHU3KX, DH24KX, DHU2KX, or DHT4KX is issued at the same time, there is an open
Related infor-
mation
(female) (1).

Defective steering relief oil pres- 3. Turn starting switch to ON position and perform troubleshooting.
1
sure sensor (HS3)
Check if normal condition is recovered when steering relief oil pressure sensor
(HS3) is replaced with a normally operating oil pressure sensor
2. Disconnect connectors JR13 and JR14 and connect T-adapter.
Defective joint connector (JR13 or 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
JR14) Between JR13 (male) (1) and (4) Max. 1 z
Resistance
connect T-adapter.
Wiring harness between V1 (female) (2) and HS3
(female) (B)
tact of connector)
Wiring harness between V2A (female) (16) and
Resistance Max. 1 z
HS3 (female) (C)
Max. 1 z
ground
connect T-adapter.
Resistance
(female) (16) to HS3 (female) (C) Min. 1 Mz
40-324 WA1200-6
Failure code [DHT8KX] Steering Oil Press. Sensor Failure

2. Disconnect connectors V1 and HS3 and connect T-adapter.
V1 (female), HS3 (female) Resistance
Defective KOMTRAX Plus control- Between V1 (2), HS3 (B) and ground Min. 1 Mz
5
V2A Voltage
Between (6) and (13) 0.7 – 5.3 V
WA1200-6 40-325
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit40-326

Action
Failure code Transmission lubricating oil pressure sensor system error
level Failure
E01 DHTAKX
An error has occurred in the transmission lubricating oil pressure sensor circuit (input signal out of
Detail of failure
range)
Action of con-
troller
Problem on
Related infor-
mation

Defective transmission lubricating 3. Turn starting switch to ON position and perform troubleshooting.
1
oil pressure sensor (MT1)
Check if normal condition is recovered when transmission lubricating oil pres-
sure sensor (MT1) is replaced with a normally operating sensor
Defective joint connector 2. Disconnect connector JT3 and connect T-adapter.
(JL11 or JT3)
Between JT3 (male) (1) and (6) Resistance Max. 1 z
2. Disconnect connectors from V2B to MT1 in turn, and connect T-adapter.
3
Voltage Max. 1 V
V1 (female), MT1 (female) Resistance
4
V2B Voltage
(4) 0.7– 5.3 V
40-326 WA1200-6
Failure code [DHTAKX] Transmission lubrication pressure sensor circuit
WA1200-6 40-327
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect
Failure code [DHTBKA] Modulation clutch pressure sensor circuit

Disconnect 40-328
Action
Failure code Transmission modulation oil pressure sensor system error
level Failure
E03 DHTBKA
An error has occurred in the transmission modulation oil pressure sensor circuit (input signal out of
Detail of failure
range)
Action of con-
troller
Problem on
If failure code DH24KX, DHU2KX, DHT8KX, or DHT4KX is issued at the same time, there is an open
Related infor-
circuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JT2
mation
(female) (1).

Defective transmission modulation 3. Turn starting switch to ON position and perform troubleshooting.
1
Check if normal condition is recovered when transmission modulation oil pres-
sure sensor (MT5) is replaced with a normally operating oil pressure sensor
2. Disconnect connectors from L02 to MT5 in turn, and connect T-adapter.
Open circuit in wiring harness Wiring harness between L02 (female) (16) and MT5
(female) (B)
tact of connector) Wiring harness between L02 (female) (8) and MT5
Resistance Max. 1 z
(female) (C)
Wiring harness between MT5 (female) (A) and
Max. 1 z
ground
2. Disconnect connectors from L02 to MT5 in turn and connect T-adapter.
Resistance
(female) (15) to MT5 (female) (3) Min. 1 Mz

2. Disconnect connectors L02 and MT5 in turn and connect T-adapter.
L02 (female), MT5 (female) Resistance
Between L02 (16), MT5 (B) and
Min. 1 Mz
ground
L02 Voltage
Between (4) and (8) 0.7– 5.3 V
40-328 WA1200-6
Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect
WA1200-6 40-329
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit
Failure code [DHTBKB] Modulation clutch pressure sensor signal short

circuit 40-3 0
Action
Failure code Transmission modulation oil pressure sensor system error
level Failure
E03 DHTBKB
An error has occurred in the transmission modulation oil pressure sensor circuit (input signal out of
Detail of failure
range)
Action of con-
troller
Problem on
If failure code DH24KX, DHU2KX, DHT8KX, or DHT4KX is issued at the same time, there is an open
Related infor-
circuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JT2
mation
(female) (1).

Defective transmission modulation 3. Turn starting switch to ON position and perform troubleshooting.
1
Check if normal condition is recovered when transmission modulation oil pres-
sure sensor (MT5) is replaced with a normally operating oil pressure sensor
2. Disconnect connectors from L02 to MT5 in turn and connect T-adapter.
(Contact with ground circuit) Max. 1 V
Voltage
(female) (8) to MT5 (female) (C) Max. 1 V

2. Disconnect connectors L02 and MT5 and connect T-adapter.
L02 (female), MT5 (female) Resistance
Between L02 (16), MT5 (B) and
Min. 1 Mz
ground
L02 Voltage
Between (4) and (8) 0.7– 5.3 V
40-330 WA1200-6
Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit
WA1200-6 40-331
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect 40-3 2

Action
Failure code Front brake oil pressure sensor system error
level Failure
E01 DHU2KA
Detail of failure An error has occurred in the front brake oil pressure sensor circuit (input signal out of range)
Action of con-
troller
Problem on q Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})
If failure code DHU3KX, DH24KX, DHT8KX, or DHT4KX is issued at the same time, there is an open
Related infor-
mation
(female) (1).

2. Disconnect sensor HR20 and replace with a normally operating sensor.
Defective front brake oil pressure 3. Turn starting switch to ON position and perform troubleshooting.
1
sensor (HR20)
Check if normal condition is recovered when front brake oil pressure sensor
(HR20) is replaced with a normally operating oil pressure sensor
2. Disconnect connectors from L04 to HR20 and from L02 to HR20 in turn,
and connect T-adapter.
Max. 1 z
tact of connector) HR20 (female) (B)
Resistance Max. 1 z
HR20 (female) (C)
Wiring harness between HR20 (female) (C) and
Max. 1 z
ground
Resistance
(female) (24) to HR20 (female) (C) Min. 1 Mz

2. Disconnect connectors L02 and HR20 and connect T-adapter.
L04 (female), HR20 (female) Resistance
Between L04 (34), HR20 (B) and
Min. 1 Mz
ground
40-332 WA1200-6
Failure code [DHU2KA] F Brake Oil press Sensor Disconnect
WA1200-6 40-333
Failure code [DHU2KB] F Brake Oil press Sensor Hot short
Failure code [DHU2KB] F Brake Oil press Sensor Hot short 40-3 4
Action
level Failure
E01 DHU2KB
Action of con-
troller
Related infor-
mation
(female) (1).

2. Replace oil pressure sensor HR20 with a normally operating oil pressure
Defective front brake oil pressure sensor
sensor (HR20)
2. Disconnect connectors between L02 and HR20 in turn and connect
(contact with +5 V circuit)
Voltage Max. 1 V
Min. 1 Mz
ground
40-334 WA1200-6
Failure code [DHU2KB] F Brake Oil press Sensor Hot short
WA1200-6 40-335
Failure code [DHU2KX] F Brake Oil press Sensor Failure
Failure code [DHU2KX] F Brake Oil press Sensor Failure 40-3 6

Action
level Failure
E01 DHU2KX
Action of con-
troller
Related infor-
mation
(female) (1).

Defective front brake oil pressure sensor
sensor (HR15)
2. Disconnect joint connectors JR13, JR14 and connect T-adapter.
Defective joint connector 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
(JR13 or JR14) Between JR13 (male) (1) and (3) Max. 1 z
Resistance
2. Connect T-adapter to connectors from V1 to HR15 and from V2A to HR15
in turn.
Wiring harness between V1 (female) (2) and HR15
(female) (B)
tact of connector)
Wiring harness between V2A (female) (7) to HR15
Resistance Max. 1 z
(female) (C)
Wiring harness between HR15 (female) (A) and
Max. 1 z
ground
2. Disconnect connectors V1 and V2A to HR15 and connect T-adapter.
Resistance

2. Disconnect connectors V1 and HR15 and connect T-adapter.
5
ler V1 (female), HR15 (female) Resistance
Between V1 (2), HR15 (B) and ground Min. 1 Mz
40-336 WA1200-6
Failure code [DHU2KX] F Brake Oil press Sensor Failure
WA1200-6 40-337
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect 40-3 8

Action
Failure code Rear brake oil pressure sensor system error
level Failure
E01 DHU3KA
Detail of failure An error has occurred in the rear brake oil pressure sensor circuit (input signal out of range)
Action of con-
troller
If failure code DH24KX, DHU2KX, DHT8KX, or DH20KX is issued at the same time, there is an open
Related infor-
mation
(female) (1).

2. Replace oil pressure sensor HR21 with a normally operating sensor
Defective rear brake oil pressure 3. Turn starting switch to ON position and perform troubleshooting.
1
sensor (HR21)
Check if normal condition is recovered when rear brake oil pressure sensor
2. Connect T-adapter to connectors from L04 to HR21 and from L02 to HR21
in turn.
HR21 (female) (B)
tact of connector)
Resistance Max. 1 z
HR21 (female) (C)
Max. 1 z
ground
Resistance

Min. 1 Mz
ground
40-338 WA1200-6
Failure code [DHU3KA] R Brake Oil press Sensor Disconnect
WA1200-6 40-339
Failure code [DHU3KB] R Brake Oil press Sensor Hot short
Failure code [DHU3KB] R Brake Oil press Sensor Hot short 40-340
Troubleshooting by failure code 40-340
WA1200-6
Action
level Failure
E01 DHU3KB
Action of con-
troller
Problem on Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})
q
Related infor-
mation
(female) (1).

Defective rear brake oil pressure sensor
sensor (HR21)
2. Disconnect connectors between L02 and HR21 in turn and connect
Voltage Max. 1 V
Min. 1 Mz
ground
40-340 WA1200-6
Failure code [DHU3KX] R Brake Oil press Sensor Failure
Failure code [DHU3KX] R Brake Oil press Sensor Failure 40-341

Action
level Failure
E01 DHU3KX
Action of con-
troller
Related infor-
mation
(female) (1).

Defective rear brake oil pressure sensor
sensor (HR16)
2. Disconnect joint connectors JR13, JR14 and connect T-adapter.
Defective joint connector 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
(JR13 or JR14) Between JR13 (male) (1) and (4) Max. 1 z
Resistance
2. Connect T-adapter to connectors from V1 to HR16 and from V2A to HR16
in turn.
Wiring harness between V1 (female) (2) and HR16
(female) (B)
tact of connector)
Wiring harness between V2A (female) (8) and
Resistance Max. 1 z
HR16 (female) (C)
Max. 1 z
ground
2. Disconnect connectors V1 and V2A to HR21 and connect T-adapter.
Resistance

5
ler V1 (female), HR16 (female) Resistance
Between V1 (2), HR16 (B) and ground Min. 1 Mz
WA1200-6 40-341
Failure code [DHU3KX] R Brake Oil press Sensor Failure
40-342 WA1200-6
Failure code [DJF1KA] Fuel level sensor circuit Disconnection
Failure code [DJF1KA] Fuel level sensor circuit Disconnection 40-343

Action
Failure code Fuel level sensor system error (input signal out of range)
level Failure
E01 DJF1KA
Detail of failure Open circuit or hot short circuit has occurred in fuel level sensor circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective fuel level sensor R05 (male) Resistance
Between (1) and (3) 0.2–5 kz
Between (1) and (2) 0–5 kz
Open circuit in wiring harness 2. Disconnect connectors FC05, R05 and connect T-adapter.
tact of connector) Wiring harness between FC05 (female) (1) and R05
Resistance Max. 1 z
(female) (1)
2. Disconnect connectors FC05, R05 and connect T-adapter.
(contact with power supply circuit)
Voltage Max. 1 V
(1)–(11) 4.9–5.1 V
WA1200-6 40-343
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit)
Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short

Circuit) 40-34
Action
Failure code AJSS/T lever system error (input signal out of range)
level Failure
E01 DK30KA
Detail of failure Open circuit or ground fault has occurred in the boom angle circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective potentiometer
R33 (male) Resistance
Open circuit in wiring harness 2. Disconnect connectors L07, R33 and connect T-adapter.
tact of connector) Wiring harness between L07 (female) (26) to R33
Resistance Max. 1 z
(female) (1)
2. Disconnect connectors L07, R33 and connect T-adapter.
4
40-344 WA1200-6
Failure code [DK30KY] Steering lever angle sensor circuit hot short
Failure code [DK30KY] Steering lever angle sensor circuit hot short 40-345
Action
Failure code AJSS/T lever system error (input signal out of range)
level Failure
E01 DK30KY
Detail of failure Hot short circuit has occurred in the boom lever potentiometer circuit
Action of con- q Steering source pressure control EPC solenoid output: OFF
troller q Control the frame angle sensor signal voltage as the input voltage.
Problem on
Effective steering speed is different to the right and left.
machine
Related infor-
monitor
mation
q Keep the joystick steering lever in the neutral position whenever it is not used.
q Keep joystick steering selector switch in "ON" position

1 Defective potentiometer
R33 (male) Resistance
Voltage Max. 1 V
3
WA1200-6 40-345
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)
Failure code [DK59KA] Boom lever potentiometer (main) (Discon-

Action
Failure code Frame angle sensor system error (input signal out of range)
level Failure
E03 DK59KA
Detail of failure Open circuit or ground fault has occurred in the boom lever potentiometer circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Defective boom lever potentiome-
1 S03 (male) Resistance
ter
(female) (3)
Resistance
Max. 1 z
(female) (4)
Resistance
(female) (22) to S03 (female) (4) Min. 1 Mz

4
40-346 WA1200-6
Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)
WA1200-6 40-347
Failure code [DK59KY] Boom lever potentiometer (main) hot short
Failure code [DK59KY] Boom lever potentiometer (main) hot short 40-348
Action Boom lever potentiometer system error (input signal out of
Failure code
E03 DK59KY (Boom bucket & AJSS controller system)
Action of con-
troller
Problem on
machine
Related infor-
monitor
mation

ter
Voltage Max. 1 V
3
40-348 WA1200-6
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure
Failure code [DK59L8] Boom lever potentiometer (main & sub) failure 40-349
Action
Failure code Bucket EPC lever potentiometer (Main): system error
level Failure
E03 DK59L8
q Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other.
Detail of failure (Bucket EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or (Bucket
EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
q Cannot recognize the bucket EPC lever position correctly.
q Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±
5%, as the regular potentiometer.
Action of con- q Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
troller neutrality ± 5%.
q Even if cause of failure disappears, machine does not become normal until bucket EPC lever is set
to N (NEUTRAL).
q Bucket moves with bucket control lever in NEUTRAL.
Problem on q If either the main potentiometer or the subpotentiometer malfunctions, the machine operates nor-
machine mally after the lever is set to neutral.
q If both the main potentiometer and subpotentiometer malfunction, the bucket does not move.
q The input condition (voltage) from the bucket EPC lever potentiometer (main) can be checked with
the monitoring function (code: 42002 BUCKET POT1).
Related infor-
q The input condition (voltage) from the bucket EPC lever potentiometer (sub) can be checked with
mation
q Method of reproducing failure code: Starting switch ON and operate bucket lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and ground Min. 1 Mz
S03 Bucket EPC lever Voltage
Between (4) and (1) Ladder at any position 4.85 to 5.15 V
Defective bucket EPC lever poten- Set lever to NEUTRAL. 2.40–2.60 V
1 tiometer
tor (internal open or short circuit) Move to TILT
3.64–4.14 V
(before detent)
Between (3) and (1)
Move to TILT
3.86–4.36 V
(detent position)
Full DUMP operation 0.64–1.14 V
Set lever to NEUTRAL. 2.40–2.60 V
Move to TILT
0.86–1.36 V
(before detent)
Between (2) and (1) Move to TILT
0.64–1.14 V
(detent position)
WA1200-6 40-349

Max. 1 z
(female) (2)
2 Wiring harness between L05 (female) (19) and S03
(open circuit or defective contact) Max. 1 z
(female) (3)
Resistance
Max. 1 z
(female) (1)
Max. 1 z
(female) (4)
Min. 1 Mz
Ground fault in wiring harness (female) (13) to S03 (female) (2)
3
(female) (19) to S03 (female) (3) Resistance Min. 1 Mz
(female) (22) to S03 (female) (4), and to circuit Min. 1 Mz
branch end
Max. 1 V
Hot short circuit in wiring harness (female) (13) to S03 (female) (2)
4
(female) (19) to S03 (female) (3) Voltage Max. 1 V

(female) (22) to S03 (female) (4), and to circuit Max. 1 V
branch end
L05 Bucket EPC lever Voltage
Move to TILT
3.64–4.14 V
(before detent)
Defective work equipment control- Move to TILT
5 3.86–4.36 V
ler (detent position)
Move to TILT
0.86–1.36 V
(before detent)
Move to TILT
0.61–1.14 V
(detent position)
40-350 WA1200-6
WA1200-6 40-351
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)
Failure code [DK5AKA] Boom lever potentiometer (sub) (Discon-

Failure code
E03 DK5AKA (Boom bucket & AJSS controller system)
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

ter
(female) (2)
Resistance
Max. 1 z
(female) (4)
Resistance

4
40-352 WA1200-6
Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)
WA1200-6 40-353
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short 40-354
Failure code
E03 DK5AKY (Boom bucket & AJSS controller system)
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

ter
Hot short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
3
40-354 WA1200-6
Failure code [DK5AKY] Boom lever potentiometer (sub) hot short
WA1200-6 40-355
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)
Failure code [DK5BKA] Bucket lever potentiometer (main) (Discon-

Action Bucket lever potentiometer system error (input signal out of
Failure code
E03 DK5BKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit or ground fault has occurred in the bucket lever potentiometer circuit
Action of con-
troller
Problem on
Dumps momentarily but then operates normally, controlled by sub potentiometer
machine
Related infor-
mation
monitor

Defective bucket lever potentiom-
eter
(female) (3)
Resistance
Max. 1 z
(female) (4)
Resistance

4
40-356 WA1200-6
Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)
WA1200-6 40-357
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short
Failure code [DK5BKY] Bucket lever potentiometer (main) hot short 40-358
Failure code
E03 DK5BKY (Boom bucket & AJSS controller system)
Action of con-
troller
Problem on
Tilts momentarily but then operates normally, controlled by sub potentiometer
machine
Related infor-
monitor
mation

eter
Hot short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting.
2
3
40-358 WA1200-6
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure
Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure 40-359
Action
Failure code Bucket EPC lever potentiometer (Main): system error
level Failure
E03 DK5BL8
q Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other.
Detail of failure (Bucket EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or (Bucket
EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
q Cannot recognize the bucket EPC lever position correctly.
q Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality ±
5 %, as the regular potentiometer.
Action of con- q Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within
troller neutrality ± 5 %.
q Even if cause of failure disappears, machine does not become normal until bucket EPC lever is set
to N (NEUTRAL).
q Bucket moves with bucket control lever in NEUTRAL.
Problem on q If either the main potentiometer or the subpotentiometer malfunctions, the machine operates nor-
machine mally after the lever is set to neutral.
q If both the main potentiometer and subpotentiometer malfunction, the bucket does not move.
q The input condition (voltage) from the bucket EPC lever potentiometer (main) can be checked with
Related infor-
q The input condition (voltage) from the bucket EPC lever potentiometer (sub) can be checked with
mation
q Method of reproducing failure code: Starting switch ON and operate bucket lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and ground Min. 1 Mz
S02 Bucket EPC lever Voltage
Defective bucket EPC lever poten- Between (4) and (1) Ladder at any position 4.85 to 5.15 V
1 tiometer
tor (internal open or short circuit)
Move to TILT
3.64–4.14 V
(before detent)
Between (3) and (1)
Move to TILT
3.86–4.36 V
(detent position)
Move to TILT
0.86–1.36 V
(before detent)
Between (2) and (1)
Move to TILT
0.64–1.14 V
(detent position)
WA1200-6 40-359

Max. 1 z
(female) (2)
(female) (3)
Resistance
Max. 1 z
(female) (1)
Max. 1 z
(female) (4)
Between ground and wiring harness from L05 Min. 1 Mz
Ground fault in wiring harness (female) (1) to S02 (female) (2)
3
(contact with ground circuit) Between ground and wiring harness from L05 Min. 1 Mz
(female) (7) to S02 (female) (3) Resistance
Min. 1 Mz
(female) (22) to S02 (female) (4), and to circuit
branch end
Max. 1 V
Hot short circuit in wiring harness (female) (1) to S02 (female) (2)
4
Max. 1 V
(female) (7) to S02 (female) (3) Voltage
(female) (22) to S02 (female) (4), and to circuit Max. 1 V
branch end
L05 Bucket EPC lever Voltage
Move to TILT
3.64–4.14 V
(before detent)
Defective boom bucket & AJSS Between (7) and (10)
5 Move to TILT
controller 3.86–4.36 V
(detent position)
Move to TILT
0.86–1.36 V
(before detent)
Move to TILT
0.61–1.14 V
(detent position)
40-360 WA1200-6
WA1200-6 40-361
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)
Failure code [DK5CKA] Bucket lever potentiometer (sub) (Discon-

Failure code
E03 DK5CKA (Bucket lever & AJSS controller system)
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

eter
Max. 1 z
Resistance
Max. 1 z
(female) (4)
Resistance
Min. 1 Mz
and perform troubleshooting.
4 L05 (female) Voltage
controller
40-362 WA1200-6
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short
Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short 40-363
Failure code
E03 DK5CKY (Bucket lever & AJSS controller system)
Detail of failure Open circuit or ground fault occurs in bucket lever potentiometer circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

eter
(female) (1) and S02 (female) (2)
3
Between (22) and ground 4.9 to 5.1 V
WA1200-6 40-363
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) 40-364

Action
Failure code Boom angle sensor system error (input signal out of range)
level Failure
E01 DKA0KA
Detail of failure Open circuit or ground fault has occurred in boom angle sensor circuit
Problem on
machine
Related infor-
monitor
mation

2. Disconnect connector F04 and connect T-adapter.
1 Defective frame angle sensor F04 (male) Resistance
Between (A) and (B) Change boom angle 0.2–5 kz
Open circuit in wiring harness 2. Disconnect connectors L05, F04 and connect T-adapter.
Resistance Max. 1 z
(female) (A)
(female) (8) to F04 (female) (A)
4
40-364 WA1200-6
Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)
WA1200-6 40-365
Failure code [DKA0KX] Boom angle sensor circuit failure
Failure code [DKA0KX] Boom angle sensor circuit failure 40-36

Action
level Failure
E01 DKA0KX
Detail of failure Open circuit, short circuit, or ground fault has occurred in boom angle sensor (potentiometer) circuit
Action of con-
Remote positioner function: OFF
troller
Problem on
Remote positioner function does not operate
machine
Related infor-
mation
monitor

Boom angle potentiometer
1 F04 (male) Resistance
(potentiometer) defective
Between (A) and (B) 0.2–5 kz
Open circuit in wiring harness Wiring harness between FC05 (female) (6) and F04
Max. 1 z
2 (wire breakage or defective con- (female) (B)
tact of connector) Wiring harness between FC01 (female) (16) and
Resistance Max. 1 z
F04 (female) (C)
Max. 1 z
F04 (female) (A)
3 Between ground and wiring harness from FC05
(female) (6) to F04 (female) (B), from FC01
(female) (10) to F04 (female) (C), from FC01
(female) (10) to F04 (female) (1)
4 Between ground and wiring harness from FC05
(female) (6) to F04 (female) (B)
Voltage
Max. 1 V
(8)–(16) 0.3–4.8 V
40-366 WA1200-6
Failure code [DKA0KX] Boom angle sensor circuit failure
WA1200-6 40-367
Failure code [DKA0KY] Boom angle sensor circuit hot short
Failure code [DKA0KY] Boom angle sensor circuit hot short 40-368
Action
level Failure
E01 DKA0KY
Problem on
machine
Related infor-
monitor
mation

Between (A) and (B) Change frame angle 0.2–5 kz
3
40-368 WA1200-6
Failure code [DKA0KY] Boom angle sensor circuit hot short
WA1200-6 40-369
Failure code [DKA0L0] Boom angle sensor failure
Failure code [DKA0L0] Boom angle sensor failure 40-370

Action
Failure code Frame angle sensor system error (input signal out of range)
level Failure
E01 DKA0L0
Detail of failure Improper positioning has occurred in boom angle sensor circuit
Action of con-
q Boom angle is not recognized correctly
troller
Problem on
Remote positioner function does not work, or semi auto digging malfunctions
machine
Related infor-
mation
monitor

Between (A) and (B) Change boom angle 0.2–5 kz
Open circuit in wiring harness 2. Disconnect connectors L05, F04 and connect T-adapter.
Resistance Max. 1 z
(female) (A)
Defective installation of boom
4 angle sensor
(Center misaligned) FC01, L05 (female) Voltage
Change boom angle
L05(8)–FC01(10) 0.5 – 4.5 V
5
40-370 WA1200-6
Failure code [DKA0L0] Boom angle sensor failure
WA1200-6 40-371
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)
Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit) 40-372

Action
Failure code Frame potentiometer system error (input signal out of range)
level Failure
E01 DKD0KA
Detail of failure Open circuit or ground fault has occurred in the circuit
Action of con-
troller
Problem on Engine cannot be started
q
machine Fine control of steering cannot be made
q
Related infor-
mation
monitor

1 Defective frame potentiometer R32 (male) Resistance
Open circuit in wiring harness 2. Disconnect connectors L05, R32 and connect T-adapter.
tact of connector) Wiring harness between L05 (female) (3) and R32
Resistance Max. 1 z
(female) (A)
(female) (3) to R32 (female) (A)
4
(10)–(22) 4.9–5.1 V
40-372 WA1200-6
Failure code [DKD0KY] Frame angle sensor circuit hot short
Failure code [DKD0KY] Frame angle sensor circuit hot short 40-373
Action
level Failure
E01 DKD0KY
Detail of failure Hot short circuit has occurred
Action of con-
troller
Problem on Engine cannot be started
q
machine Fine control of steering cannot be made
q
Related infor-
mation
monitor

1 Defective frame potentiometer R32 (male) Resistance
Voltage Max. 1 V
(female) (3) to R32 (female) (A)
3
(10)–(22) 4.9–5.1 V
WA1200-6 40-373
Failure code [DKD0KZ] Frame and steering angle sensor failure
Failure code [DKD0KZ] Frame and steering angle sensor failure 40-374
Action
level Failure
E01 DKD0KZ
Detail of failure Open circuit or ground fault has occurred in frame angle sensor circuit
Problem on
machine
Related infor-
monitor
mation

2. Disconnect connector R32, R32 and connect T-adapter.
1 Defective frame potentiometer S30, R32 (male) Resistance
Defective installation of frame 3. Turn starting switch to ON position and perform troubleshooting.
2 angle sensor
(Center misaligned)
(3)–(10) Change frame angle
0.5 – 4.5 V
(3)–(9)
3
(10)–(22) 4.9–5.1 V
40-374 WA1200-6
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect
Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect 40-375

Action
Failure code Pitch angle sensor system error (input signal out of range)
level Failure
E01 DKH0KA
Detail of failure Open circuit or ground fault has occurred in the pitch angle sensor circuit
Action of con- q Controls machine based on information obtained before occurrence of failure
Problem on
machine
Related infor-
mation
monitor

1 Defective pitch angle sensor 3. Turn the starting switch to OFF position, then perform troubleshooting.
Replace with a normally operating sensor Failure code disappears
Open circuit in wiring harness Wiring harness between L02 (female) (7) and L141
Max. 1 z
2 (wire breakage or defective con- (female) (B)
tact of connector) Wiring harness between L02 (female) (4) and L141
Resistance Max. 1 z
(female) (A)
Max. 1 z
L141 (female) (C)
(female) (7) to L141 (female) (B)
Resistance
Min. 1 Mz
(female) (4) to L141 (female) (A)
WA1200-6 40-375
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short 40-376
Action
Failure code Angle sensor system error (input signal out of range)
level Failure
E01 DKH0KB
Detail of failure Hot short circuit occurs in angle sensor circuit.
Action of con-
q Controls machine based on information obtained before occurrence of failure,
troller
Problem on
machine
Related infor-
mation

2. Disconnect connector L141 and replace current sensor with normally oper-
ating sensor.
1 Defective angle sensor
Replace current sensor with normally operating
sensor
(female) (7) and L141 (female) (B)
Between (7) and ground 4.9 to 5.1 V
40-376 WA1200-6
Failure code [DKH0KB] Angle sensor circuit (FR) Hot short
WA1200-6 40-377
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect 40-378

Action
Failure code Pitch angle sensor system error (input signal out of range)
level Failure
E01 DKH1KA
Detail of failure Open circuit or ground fault has occurred in the pitch angle sensor circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect sensor L142 and replace with a normally operating sensor.
1 Defective frame angle sensor 3. Turn starting switch to ON position and perform troubleshooting.
Replace with a normally operating sensor Failure code disappears
Max. 1 z
2 (wire breakage or defective con- Wiring harness between L02 (female) (1) and L142
Max. 1 z
Resistance
Max. 1 z
(female) (A)
Max. 1 z
L142 (female) (C)
Ground fault in wiring harness Min. 1 Mz
3 (female) (1) to L142 (female) (B)
(female) (1) to L142 (female) (B)
Min. 1 Mz
(female) (4) to L142 (female) (A)
(1)–(4) 4.9–5.1 V
40-378 WA1200-6
Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect
WA1200-6 40-379
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short 40-380
Action
Failure code Angle sensor system error (input signal out of range)
level Failure
E01 DKH1KB
Detail of failure Hot short circuit occurs in angle sensor circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Disconnect sensor L142 and replace current sensor with normally oper-
ating sensor.
1 Defective frame angle sensor
Replace current sensor with normally operating
sensor
(female) (1) and L142 (female) (B)
(1) to (4) 4.9 to 5.1 V
40-380 WA1200-6
Failure code [DKH1KB] Angle sensor circuit (LR) Hot short
WA1200-6 40-381
Failure code [DLE2KA] Engine Speed Sensor Disconnection
Failure code [DLE2KA] Engine Speed Sensor Disconnection 40-382

Action
Failure code Engine speed sensor system error
level Failure
E03 DLE2KA
Detail of failure Open circuit or hot short circuit has occurred in engine speed sensor circuit
Action of con- q Travels with engine speed at 2,100 rpm
troller q ECMV does not operate
Problem on
Gear shifting shocks are made
machine
Related infor- a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting,
mation or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor

1 Defective engine speed sensor
T17 (male) Resistance
Between (1) and (2) 100–500 z
2. Disconnect connector L03, T17 and connect T-adapter.
Max. 1 z
Resistance
Max. 1 z
(female) (2)
(contact with power supply circuit) Max. 1 V
Voltage
Max. 1 V
without turning stating switch to ON position.
4 Defective transmission controller L03(female) Resistance
40-382 WA1200-6
Failure code [DLE2KA] Engine Speed Sensor Disconnection
WA1200-6 40-383
Failure code [DLE2LC] Engine Speed Sensor Short Circuit
Failure code [DLE2LC] Engine Speed Sensor Short Circuit 40-384

Action
Failure code Engine speed sensor system error
level Failure
E03 DLE2LC
Detail of failure Ground fault has occurred in engine speed sensor circuit
Action of con-
Judges as engine is stopped
troller
Problem on
ECMV does not operate
machine

1 Defective engine speed sensor
Between (1) and (2) 100–500 z
2. Disconnect connector L03, T17 and connect T-adapter.
40-384 WA1200-6
Failure code [DLE2LC] Engine Speed Sensor Short Circuit
WA1200-6 40-385
Failure code [DLF6LC] Tire speed sensor circuit
Failure code [DLF6LC] Tire speed sensor circuit 40-386

WA1200-6
Action
Failure code Tire speed sensor system error
level Failure
E03 DLF6LC
Detail of failure Open circuit or hot short circuit has occurred in tire speed sensor circuit
Action of con-
Judges as tire speed is zero
troller
Problem on
Judges as tire is slipping
machine

1 Defective tire speed sensor
F15 (male) Resistance
Between (1) and (2) 100–500 z
2 (wire breakage or defective con- Wiring harness between L03 (female) (37) and F15
Max. 1 z
Resistance
Wiring harness between L03 (female) (39) and F15
Max. 1 z
(female) (C)
2. Disconnect connectors L03, F15, V1 in turn, and connect T-adapter.
Voltage Max. 1 V
40-386 WA1200-6
Failure code [DLF6LC] Tire speed sensor circuit
WA1200-6 40-387
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect 40-38

Action
Failure code Modulation clutch speed sensor system error
level Failure
E03 DLFALC
Detail of failure Open circuit or hot short circuit has occurred in modulation clutch speed sensor system
Action of con-
Assumes that modulation clutch outlet speed is 2100 rpm
troller
Problem on
Automatic shift does not operate
machine
Related infor-
mation
monitor

Defective modulation clutch outlet
1 T15 (male) Resistance
speed sensor
Between (1) and (2) 500–1000 kz
2. Disconnect connectors L03, T16 and connect T-adapter.
Max. 1 z
Resistance
Max. 1 z
(female) (2)
Voltage Max. 1 V
L03(female) Voltage
during illuminance decrease adjust-
ment
40-388 WA1200-6
Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect
WA1200-6 40-389
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit 40-390
Action
Failure code Modulation clutch speed sensor system error
level Failure
E03 DLFALC
Detail of failure Ground fault has occurred in modulation clutch speed sensor system
Action of con-
Assumes that modulation clutch outlet speed is 2100 rpm
troller
Problem on
Automatic shift does not operate
machine
Related infor-
mation
monitor

Defective modulation clutch outlet
speed sensor
Between (1) and (2) 500–1000 kz
L03(female) Voltage
40-390 WA1200-6
Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit
WA1200-6 40-391
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit 40-392
Action
Failure code Travel speed sensor system error
level Failure
E03 DLT4KB
Detail of failure Ground fault has occurred in the travel speed sensor circuit
Tire slip prevention control is cancelled
q
Action of con-
Modulation clutch control is cancelled (clutch is engaged directly)
q
troller
q NC solenoid: OFF
q Driving force does not change when driving force control dial is operated.
Problem on
q Tire slip control does not work.
machine
q Travel speed cannot be controlled
Related infor-
mation
monitor

1 Defective travel speed sensor T15 (male) Resistance
Between (1) and (2) 500–1000 kz
L03(female) Voltage
40-392 WA1200-6
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit
WA1200-6 40-393
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection 40-394
Action
Failure code Travel speed sensor system error
level Failure
E03 DLT4KX
Detail of failure Open circuit or hot short circuit has occurred in transmission output shaft speed circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

1 Defective travel speed sensor
Between (1) and (2) 500–1000 kz
Max. 1 z
Resistance
Max. 1 z
(female) (2)
Voltage Max. 1 V
(female) (1)
L03(female) Voltage
40-394 WA1200-6
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection
WA1200-6 40-395
Failure code [DT20KB] Transmission cut off indicator Output short circuit
Failure code [DT20KB] Transmission cut off indicator Output short

circuit 40-396
Action Transmission cutoff switch system error (input signal out of
Failure code
E01 DT20KB (Transmission controller system)
Detail of failure Open circuit or ground fault occurs in built-in indicator of transmission cutoff switch.
Action of con-
troller
Problem on
Cutoff indicator does not light up.
machine
Related infor-
T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting
mation
is made while failure is appearing.

2. Disconnect switch S23 and replace it with normally operating switch.
Defective transmission cutoff
switch
Replace current switch with normally
operating switch
Open circuit in wiring harness 2. Disconnect connectors L04, S23 and connect T-adapter.
2 (wire breakage or defective con- 3. Turn starting switch to OFF position, then perform troubleshooting.
tact of connector) Wiring harness between L04 (female) (8) and S23
Resistance Max. 1 z
(female) (2)
40-396 WA1200-6
Failure code [DT21KB] Speed Control indicator Output short circuit
Failure code [DT21KB] Speed Control indicator Output short circuit 40-397
Action Travel speed control indicator system error (input signal out of
Failure code
E01 DT21KB (Transmission controller system)
Detail of failure An error occurs in travel speed control indicator circuit.

Action of con-
troller
Problem on
Travel speed control indicator does not light up.
machine
Related infor-
mation

2. Disconnect switch FC22 and replace it with normally operating switch.
Defective travel speed control indi-
cator
Replace current switch with normally
operating switch
(female) (18) and FC22 (female) (6)
WA1200-6 40-397
Failure code [DUM8KB] VHMS Operation lamp Short Circuit
Failure code [DUM8KB] VHMS Operation lamp Short Circuit 40-398

Action
Failure code Boom kick-out solenoid system error
level Failure
E01 DUM8KB
Detail of failure Ground fault or hot short circuit occurs in circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

2. Disconnect switches RA10, RA11 and replace them with normally oper-
ating switches.
1 Defective lift arm kick-out relay
Replace current switches with nor-
mally operating switches
2. Disconnect connectors V1, RA10, RA11 and connect T-adapter.
2 Between ground and wiring harness between V1
(female) (14) and RA10 (female) (2)
Resistance
Min. 1 Mz
2. Disconnect connectors V1, RA10, RA11 and connect T-adapter.
3 Between ground and wiring harness between V1
(contact with +24 V circuit) Max. 1 V
Voltage
Max. 1 V
40-398 WA1200-6
Failure code [DUM8KB] VHMS Operation lamp Short Circuit
WA1200-6 40-399
Failure code [DV00KY] Buzzer circuit hotshort (for usually)
Failure code [DV00KY] Buzzer circuit hotshort (for usually) 40-40

Action
Failure code Alarm buzzer: short circuit
level Failure
E01 DV00KY
Detail of failure q Hot short is detected in the alarm buzzer output circuit.
q Stops alarm buzzer output.
Action of con-
troller
to OFF position.
Problem on
q Alarm buzzer does not sound
machine
q The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code:
Related infor-
40925, D-OUT-0).
mation

L42 (female) Starting switch Voltage
Defective alarm buzzer Between (1) and ground ON 20 to 30 V
1
For 2 secs after ON
20 to 30 V
(Alarm buzzer sounds.)
Between (1) and (2) For 2 to 3 secs after ON
(Alarm buzzer does not Max. 1 V
sound.)
2. Disconnect connectors FC01, L42 and connect T-adapter.
Voltage Max. 1 V
FC01 Starting switch Voltage
3 Defective machine monitor ON 20 to 30 V

For 2 secs after ON
Max. 1 V
Between (14) and ground (Alarm buzzer sounds.)
For 2 to 3 secs after ON
(Alarm buzzer does not 20 to 30 V
sound.)
40-400 WA1200-6
Failure code [DV00KY] Buzzer circuit hotshort (for usually)
WA1200-6 40-401
Failure code [DV01KY] Buzzer circuit hotshort (for special)
Failure code [DV01KY] Buzzer circuit hotshort (for special) 40-402

Action
Failure code Alarm buzzer: short circuit
level Failure
E01 DV01KY
Detail of failure q Hot short is detected in the alarm buzzer output circuit.
q Stops alarm buzzer output.
Action of con-
troller
to OFF position.
Problem on
q Alarm buzzer does not sound
machine
q The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code:
Related infor-
40925, D-OUT-0).
mation

L43 (female) Starting switch Voltage
Defective alarm buzzer Between (1) and ground ON 20 to 30 V
1
For 2 secs after ON
20 to 30 V
(Alarm buzzer sounds.)
Between (1) and (2) For 2 to 3 secs after ON
(Alarm buzzer does not Max. 1 V
sound.)
2. Disconnect connectors FC01, L43 and connect T-adapter.
Voltage Max. 1 V
FC01 Starting switch Voltage
3 Defective machine monitor ON 20 to 30 V

For 2 secs after ON
Max. 1 V
Between (14) and ground (Alarm buzzer sounds.)
For 2 to 3 secs after ON
(Alarm buzzer does not 20 to 30 V
sound.)
40-402 WA1200-6
Failure code [DV01KY] Buzzer circuit hotshort (for special)
WA1200-6 40-403
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection
Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection40-404

Action
Failure code F bypass valve system error (open circuit)
level Failure
E03 DW23KA
Detail of failure Open circuit occurs in F bypass valve circuit
Action of con-
Interrupts solenoid output
troller
Problem on
Shifting shocks are noticed at F clutch and time to engage becomes longer (eventually engages).
machine
Related infor-
mation

2. Disconnect switch T22 and connect T-adapter.
1 Defective F bypass solenoid T22 (male) Resistance
Open circuit in wiring harness 2. Disconnect connectors L04, T22 and connect T-adapter.
tact of connector) Wiring harness between L04 (female) (7) and T22
Resistance Max. 1 z
(female) (1)
L04 (male) Resistance
40-404 WA1200-6
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit
Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit 40-405
Action
Failure code F bypass valve system error (ground fault)
level Failure
E03 DW23KB
Detail of failure Ground fault occurs in F bypass valve circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

WA1200-6 40-405
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short
Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot

short 40-406
Action
Failure code F bypass valve system error (hot short circuit)
level Failure
E03 DW23KY
Detail of failure Hot short circuit occurs in F bypass valve circuit.
Action of con-
Interrupts solenoid output.
troller
Problem on
machine
Related infor-
mation
is performing while failure is appearing.

Voltage Min. 1 V
40-406 WA1200-6
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection
Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection40-407

Action
Failure code R bypass valve system error (open circuit)
level Failure
E03 DW24KA
Detail of failure Open circuit occurs in R bypass valve circuit.
Action of con-
troller
Problem on
Shifting shocks are noticed at R clutch and time to engage becomes longer (eventually engages).
machine
Related infor-
mation
is performed while failure is appearing.

1 Defective R bypass solenoid T21 (male) Resistance
Resistance Max. 1 z
(female) (1)
WA1200-6 40-407
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit
Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit 40-408
Action
Failure code R bypass valve system error (ground fault)
level Failure
E03 DW24KB
Detail of failure Ground fault occurs in R bypass valve circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

40-408 WA1200-6
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short
Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot

short 40-409
WA1200-6
Action
Failure code R bypass valve system error (hot short circuit)
level Failure
E03 DW24KY
Detail of failure Hot short circuit occurs in R bypass valve circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
is performed while failure is appearing

Voltage Max. 1 V
WA1200-6 40-409
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection
Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnec-

tion 40-410
Action
Failure code 1st bypass valve system error (open circuit)
level Failure
E03 DW25KA
Detail of failure Open circuit occurs in 1st bypass valve circuit.
Action of con-
troller
Problem on
Shifting shocks are noticed at 1st clutch and time to engage becomes longer (eventually engages).
machine
Related infor-
mation
is ferformed while failure is appearing.

1 Defective 1st bypass solenoid T20 (male) Resistance
Resistance Max. 1 z
(female) (1)
40-410 WA1200-6
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit
Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit40-41
Action
Failure code 1st bypass valve system error (ground fault)
level Failure
E03 DW25KB
Detail of failure Ground fault occurs in 1st bypass valve circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

Between (1) and (2) 5 to15 z
WA1200-6 40-411
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short
Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot
short 40-412
Action
Failure code 1st bypass valve system error (hot short circuit)
level Failure
E03 DW25KY
Detail of failure Hot short circuit occurs in 1st bypass valve circuit.
Action of con-
troller
Problem on
machine
Related infor-
mation

3. Turn starting switch to OFF positon, then perform troubleshooting.
Voltage Max. 1 V
40-412 WA1200-6
Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection
Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection 40-413

Action Boom RAISE EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4PKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in boom RAISE EPC solenoid (1) circuit
Action of con-
q Boom LOWER EPC solenoid (1) cannot be energized
troller
Problem on
Boom LOWER speed is slow
machine
Related infor-
mation
monitor

Defective boom RAISE EPC sole-
noid (1)
Open circuit in wiring harness 2. Disconnect connectors L07, HR23 and connect T-adapter.
tact of connector) Wiring harness between L07 (female) (28) and
Resistance Max. 1 z
HR23 (female) (1)
3
(28)–(13) 4.9–5.1 V
WA1200-6 40-413
Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault
Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault 40-414
Action Boom Raise EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4PKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault occurs in boom Raise EPC solenoid (1) circuit.
Action of con-
troller
Problem on
Boom Raise speed is slow.
machine
Related infor-
mation

Defective boom Raise EPC sole-
noid (1)
Between (1) and (2) 5 to 15 kz
(female) (28) and HR23 (female) (1)
3
(28) to (13) 4.9 to 5.1 V
40-414 WA1200-6
Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short
Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short 40-415
Failure code
E03 DW4PKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit occurs in boom Raise EPC solenoid (1) circuit.
Action of con-
troller
Problem on
Boom Raise speed is slow.
machine
Related infor-
T-adapter is inserted, or when T-adapter is removed and connecter is restored as troubleshooting
mation

Defective boom Raise EPC sole-
noid (1)
Voltage Max. 1 V
3
(28) to (13) 4.9 to 5.1 V
WA1200-6 40-415
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection
Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection 40-416
Action Boom Lower EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4QKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit occurs in boom Lower EPC solenoid (1) circuit.
Action of con-
q Boom Lower EPC solenoid (1) cannot be energized.
troller
Problem on
Boom Lower speed is slow.
machine
Related infor-
T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored
mation
as troubleshooting is performed while failure is appearing.

1 Defective EPC solenoid (1) HR24 (male) Resistance
Resistance Max. 1 z
HR24 (female) (1)
3
(38) to (13) 4.9 to 5.1 V
40-416 WA1200-6
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit
Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit 40-417
Action Boom LOWER EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4QKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault has occurred in boom LOWER EPC solenoid (1) circuit
Action of con-
troller
Problem on
machine
Related infor-
monitor
mation

1 Defective frame angle sensor HR24 (male) Resistance
3
(38)–(13) 4.9–5.1 V
WA1200-6 40-417
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short
Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short 40-418
Failure code
E03 DW4QKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit has occurred in boom LOWER EPC solenoid (1) circuit
Action of con-
troller
Problem on
machine
Related infor-
monitor
mation

Voltage Max. 1 V
3
(38)–(13) 4.9–5.1 V
40-418 WA1200-6
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection
Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection 40-419
Action Bucket tilt EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4RKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit occurs in bucket tilt EPC solenoid (1) circuit.
Action of con-
q Bucket tilt EPC solenoid (1) cannot be energized.
troller
Problem on
Bucket tilt speed is slow.
machine
Related infor-
T-adapter is inserted, or when T-adapter is removed and connecter is restored as troubleshooting
mation

Defective bucket Tilt EPC solenoid
(1)
tact of connector) Wiring harness between L07 (female) (5) and HR25
Resistance Max. 1 z
(female) (1)
3
(5) to (3) 4.9 to 5.1 V
WA1200-6 40-419
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault
Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault 40-420
Failure code
E03 DW4RKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault occurs in bucket tilt EPC solenoid (1) circuit.
Action of con-
troller
Problem on
Bucket tilt speed is slow.
machine
Related infor-
mation
is performed while failure is appearing

(1)
3
(5) to (3) 4.9 to 5.1 V
40-420 WA1200-6
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short
Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short 40-421
Failure code
E03 DW4RKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit occurs in bucket tilt EPC solenoid (1) circuit.
Action of con-
troller
Problem on
Bucket tilt speed becomes slower.
machine
Related infor-
mation

(1)
Voltage Max. 1 V
(female) (5) and, HR25 (female) (1)
3
(5) to (3) 4.9 to 5.1 V
WA1200-6 40-421
Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection
Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection 40-42

Action Bucket DUMP EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4SKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in bucket DUMP EPC solenoid (1) circuit
Action of con-
q Bucket DUMP EPC solenoid (1) cannot be energized
troller
Problem on
Bucket DUMP speed is slow
machine
Related infor-
mation
monitor

Defective bucket DUMP EPC
solenoid (1)
Resistance Max. 1 z
HR26 (female) (1)
3
(15)–(3) 4.9–5.1 V
40-422 WA1200-6
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit
Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit 40-423
Action Bucket Dump EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4SKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault occurs in bucket Dump EPC solenoid (1) circuit.
Action of con-
troller
Problem on
Bucket Dump speed becomes slower.
machine
Related infor-
mation

Defective bucket Dump EPC sole-
noid (1)
3
(15) to (3) 4.9 to 5.1 V
WA1200-6 40-423
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short
Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short 40-424
Action Bucket Dump EPC solenoid (1) system error (input signal out of
Failure code
E03 DW4SKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit occurs in bucket Dump EPC solenoid (1) circuit.
Action of con-
troller
Problem on
Bucket Dump speed becomes slower.
machine
Related infor-
mation

Defective bucket Dump EPC sole-
noid (1)
Voltage Max. 1 V
3
(15) to (3) 4.9 to 5.1 V
40-424 WA1200-6
Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection
Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection 40-425

Action Boom RAISE EPC solenoid (2) system error (input signal out of
Failure code
E03 DW5PKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in boom RAISE EPC solenoid (2) circuit
Action of con-
q Boom RAISE EPC solenoid (1) cannot be energized
troller
Problem on
Boom RAISE speed is slow
machine
Related infor-
mation
monitor

Defective boom RAISE EPC sole-
noid (2)
Resistance Max. 1 z
(female) (1)
3
(6)–(3) 4.9–5.1 V
WA1200-6 40-425
Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault
Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault 40-426
Failure code
E03 DW5PKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault occurs in boom Raise EPC solenoid (2) circuit.
Action of con-
troller
Problem on
Boom Raise speed becomes slower.
machine
Related infor-
mation

3
(6) to (3) 4.9 to 5.1 V
40-426 WA1200-6
Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short
Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short 40-427
Failure code
E03 DW5PKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit occurs in boom Raise EPC solenoid (2) circuit.
Action of con-
troller
Problem on
Boom Raise speed becomes slower.
machine
Related infor-
mation

Voltage Max. 1 V
3
(6) to (3) 4.9 to 5.1 V
WA1200-6 40-427
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection
Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection40-428

Failure code
E03 DW5QKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in boom LOWER EPC solenoid (2) circuit
Action of con-
q Boom LOWER EPC solenoid (2) cannot be energized
troller
Problem on
machine
Related infor-
mation
monitor

Defective boom LOWER EPC
solenoid (2)
Resistance Max. 1 z
HR28 (female) (1)
3
(16)–(13) 4.9–5.1 V
40-428 WA1200-6
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault
Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault 40-429
Failure code
E03 DW5QKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault occurs in boom Lower EPC solenoid (2) circuit.
Action of con-
troller
Problem on
Boom Lower speed becomes slower.
machine
Related infor-
mation

3
(16) to (13) 4.9 to 5.1 V
WA1200-6 40-429
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short
Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short 40-430
Failure code
E03 DW5QKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit occurs in boom Lower EPC solenoid (2) circuit.
Action of con-
troller
Problem on
Boom Lower speed becomes slower.
machine
Related infor-
mation

Defective boom Lower EPC sole-
noid (2)
Voltage Max. 1 V
3
(16) to (13) 4.9 to 5.1 V
40-430 WA1200-6
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection
Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection 40-431

WA1200-6
Action Bucket TILT EPC solenoid (2) system error (input signal out of
Failure code
E03 DW5RKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in bucket TILT EPC solenoid (2) circuit
Action of con-
q Bucket TILT EPC solenoid (2) cannot be energized
troller
Problem on
Bucket TILT speed is slow
machine
Related infor-
mation
monitor

Defective bucket TILT EPC sole-
noid (2)
Resistance Max. 1 z
HR29 (female) (1)
3
(25)–(3) 4.9–5.1 V
WA1200-6 40-431
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault
Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault 40-432
Action Bucket Tilt EPC solenoid (2) system error (input signal out of
Failure code
E03 DW5RKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault occurs in bucket Tilt EPC solenoid (2) circuit.
Action of con-
troller
Problem on
Bucket tilt speed becomes slower.
machine
Related infor-
mation

(2)
3
(25) to (3) 4.9 to 5.1 V
40-432 WA1200-6
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short
Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short 40-43
Action Bucket TILT EPC solenoid (2) system error (input signal out of
Failure code
E03 DW5RKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit has occurred in bucket TILT EPC solenoid (2) circuit
Action of con-
troller
Problem on
Bucket TILT speed becomes slower
machine
Related infor-
mation
monitor

Defective bucket TILT EPC sole-
noid (2)
Voltage Max. 1 V
3
(25)–(3) 4.9–5.1 V
WA1200-6 40-433
Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection
Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection 40-434

Failure code
E03 DW5SKA (Boom bucket & AJSS controller system)
Detail of failure Open circuit has occurred in bucket DUMP EPC solenoid (2) circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

solenoid (2)
Resistance Max. 1 z
HR30 (female) (1)
3
(35)–(3) 4.9–5.1 V
40-434 WA1200-6
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit
Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit 40-435
Failure code
E03 DW5SKB (Boom bucket & AJSS controller system)
Detail of failure Ground fault has occurred in bucket DUMP EPC solenoid (2) circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

solenoid (2)
2. Disconnect connector L07 and connectors to ON in turn, and connect
T-adapter.
controller
(35)–(3) 4.9–5.1 V
WA1200-6 40-435
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short 40-436
Failure code
E03 DW5SKY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit has occurred in bucket DUMP EPC solenoid (2) circuit
Action of con-
troller
Problem on
Bucket DUMP speed becomes slower
machine
Related infor-
mation
monitor

solenoid (2)
Voltage Max. 1 V
2. Disconnect connector L07 and connectors to ON in turn, and connect
T-adapter.
controller
(35)–(3) 4.9–5.1 V
40-436 WA1200-6
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection 40-437

Action
Failure code R drain valve system error
level Failure
E03 DWJ2KA
Detail of failure Open circuit has occurred in the R drain valve circuit
Action of con-
R clutch drain valve solenoid output: OFF
troller
Problem on
R clutch disengaging time becomes longer
machine
Related infor-
mation
monitor

Defective R clutch drain valve
solenoid
2 (wire breakage or defective con- Wiring harness between T23 (female) (2) and
Max. 1 z
tact of connector) ground
Resistance
Max. 1 z
(female) (1)
ment
WA1200-6 40-437
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit 40-438
Action
level Failure
E03 DWJ2KB
Detail of failure Ground fault has occurred in the R drain valve circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

solenoid
Resistance Max. 1 z
ment
40-438 WA1200-6
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short40-439
Action
level Failure
E03 DWJ2KY
Detail of failure Hot short circuit has occurred in the R drain valve circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

solenoid
Voltage Max. 1 V
Between (37) and ground Max. 1V
WA1200-6 40-439
Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection
Failure code [DWM1KA] Work equipment neutral lock solenoid discon-

nection 40-4 0
Action
Failure code Work equipment neutral lock solenoid: Open circuit
level Failure
E03 DWM1KA
q Because of open circuit of work equipment neutral lock solenoid system, no current flows when
Detail of failure
work equipment neutral lock solenoid power output is turned ON.
q Stops outputting the signal from each work equipment EPC solenoid according to the input signal
Action of con-
from the work equipment lock lever.
troller
Problem on
q Each work equipment EPC solenoid lock for the work equipment lock lever works normally.
machine
q Power output condition (ON/OFF) to work equipment neutral lock solenoid can be checked with
Related infor- monitoring function (Code: 40952, D-OUT-0).
mation q Method of reproducing failure code: Set the starting switch to ON position + Set the work equip-
ment lock lever toLOCK position

Defective work equipment neutral
1 lock solenoid
(Internal open circuit) HR22 (male) Resistance
2 Wiring harness between L07 (female) (7) and HR22
(female) (1)
Resistance
Max. 1 z
ground
3
Between (7) and ground 35–45 kz
40-440 WA1200-6
Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit
Failure code [DWM1KB] Work equipment neutral lock solenoid short

circuit 40-4 1
Action
Failure code Work equipment neutral lock solenoid: ground fault
level Failure
E03 DWM1KB
q Due to ground fault in work equipment neutral lock solenoid system, no current flows when work
Detail of failure
equipment neutral lock solenoid is energized.
Action of con-
troller
Problem on
machine

1 lock solenoid
Resistance Max. 1 z
3
WA1200-6 40-441
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short
Failure code [DWM1KY] Work equipment neutral lock solenoid hot short40-4 2
Action
Failure code Work equipment neutral lock solenoid: hot short circuit
level Failure
E03 DWM1KY
q Due to hot short circuit in work equipment neutral lock solenoid system, no current flows when work
Detail of failure
equipment neutral lock solenoid is energized.
Action of con-
troller
Problem on
machine

1 lock solenoid
Hot short circuit in wiring harness 2. Disconnect connectors L07, HR22 and connect T-adapter.
2 (defective contact with power sup- 3. Turn starting switch to ON position and perform troubleshooting.
ply circuit) Between ground and wiring harness from L07
Voltage Max. 1 V
3
40-442 WA1200-6
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection
Failure code [DWN6KA] Magnet detent solenoid (Boom raise) discon-

nection 40-4 3
Action
Failure code Lift arm RAISE magnet detent solenoid: Open circuit
level Failure
E03 DWN6KA
q When outputting current to lift arm RAISE magnet detent solenoid, no current flows due to open
Detail of failure
circuit in power supply circuit for lift arm RAISE magnet detent solenoid.
q Keeps outputting current to lift arm RAISE magnet detent solenoid normally.
Action of con-
q Stops outputting signal voltage to remote positioner RAISE stop pilot lamp.
troller
Problem on q The lift arm RAISE remote positioner does not work.
machine q Lift arm control lever is not held at RAISE detent position.
q Output (ON/OFF) to lift arm RAISE magnet detent solenoid can be checked by using monitoring
Related infor-
function. (Code: 40952 D-OUT-1)
mation
q Method of reproducing failure code: Start the engin + Set the lever to lift arm raise detent position

Defective lift arm RAISE magnet
1 detent solenoid
(Internal open circuit) S05 (male) Resistance
(female) (1)
Resistance
Wiring harness between S05 (female) (2) and
Max. 1 z
ground
3 L07 Lift arm control lever Voltage
controller
NEUTRAL position Max. 1 V
Detent operation, RAISE 20 to 30 V
WA1200-6 40-443
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit
Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short

circuit 40-4 4
Action
Failure code Lift arm RAISE magnet detent solenoid: ground fault
level Failure
E03 DWN6KB
q Due to ground fault in lift arm RAISE magnet detent solenoid power supply system, no current
Detail of failure
flows when lift arm RAISE magnet detent solenoid is energized.
Action of con-
troller
Related infor-
mation

1 detent solenoid
controller
40-444 WA1200-6
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short
Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short 40-4 5
Action
Failure code Lift arm RAISE magnet detent solenoid: hot short circuit
level Failure
E03 DWN6KY
q Due to hot short circuit in lift arm RAISE magnet detent solenoid power supply system, no current
Detail of failure
flows when lift arm RAISE magnet detent solenoid is energized.
Action of con-
troller
Related infor-
mation

1 detent solenoid
Hot short circuit in wiring harness 2. Disconnect connectors L07, S05 and connect T-adapter.
2 (Defective contact with power sup- 3. Turn starting switch to ON position and perform troubleshooting.
Voltage Max. 1 V
controller
WA1200-6 40-445
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection
Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnec-

tion 40-4 6
Action
Failure code Lift arm FLOAT magnet detent solenoid: Open circuit
level Failure
E03 DWN7KA
q When outputting current to lift arm FLOAT magnet detent solenoid, no current flows due to open
Detail of failure
circuit in power supply circuit for lift arm FLOAT magnet detent solenoid.
q Keeps outputting current to lift arm FLOAT magnet detent solenoid normally.
Action of con-
q Stops outputting signal voltage to remote positioner LOWER stop pilot lamp.
troller
Problem on q The lift arm LOWER remote positioner does not work.
machine q Lift arm control lever is not held at FLOAT detent position.
q Output (ON/OFF) to lift arm FLOAT magnet detent solenoid can be checked by using monitoring
Related infor-
mation
q Method of reproducing failure code: Start the engine + Set the lever to lift arm float detent position

Defective lift arm FLOAT magnet
1 detent solenoid
(female) (1)
Resistance
Wiring harness between S06 (female) (2) and
Max. 1 z
ground
controller
FLOAT detent operation 20 to 30 V
40-446 WA1200-6
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit
Failure code [DWN7KB] Magnet detent solenoid (Boom float) short

circuit 40-4 7
Action
Failure code Lift arm FLOAT magnet detent solenoid: ground fault
level Failure
E03 DWN7KB
q Due to ground fault in lift arm FLOAT magnet detent solenoid power supply system, no current
Detail of failure
flows when lift arm FLOAT magnet detent solenoid is energized.
Action of con-
troller
Related infor-
mation

1 detent solenoid
Ground fault in wiring harness 2. Disconnect connectors L07, S06 and connect T-adapter.
2 (Defective contact with ground cir- 3. Turn the starting switch to OFF position, then perform troubleshooting.
cuit) Between ground and wiring harness from L07
controller
WA1200-6 40-447
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short
Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short 40-4 8
Action
Failure code Lift arm FLOAT magnet detent solenoid: hot short circuit
level Failure
E03 DWN7KY
q Due to hot short circuit in lift arm FLOAT magnet detent solenoid power supply system, no current
Detail of failure
flows when lift arm FLOAT magnet detent solenoid is energized.
Action of con-
troller
Related infor-
mation

1 detent solenoid
Hot short circuit in wiring harness 2. Disconnect connectors L07, S06 and connect T-adapter.
2 (defective contact with power sup- 3. Turn starting switch to ON position and perform troubleshooting.
Voltage Max. 1 V
controller
40-448 WA1200-6
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection
Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnec-

tion 40-4 9
Action
Failure code Bucket TILTmagnet detent solenoid: Disconnection
level Failure
E03 DWN8KA
q Due to open circuit in bucket TILT magnet detent solenoid power supply system, abnormal voltage
Detail of failure
exists when bucket TILT magnet detent solenoid is deenergized
Action of con- q Stops outputting the signal to the bucket TILT magnet detent solenoid.
q If the bucket TILT detent operation performed, the detent condition is not automatically released
Problem on (can be manually released).
machine q If you do not perform bucket detent operation, return of the bucket lever to NEUTRAL is affected
by the magnetic attraction (lever control performance grows worse).
q The output condition (ON/OFF) to the bucket TILT magnet detent solenoid can be checked with
Related infor-
the monitoring function (Code: 40952, D-OUT-3).
mation

Defective bucket TILT magnet 3. Turn the starting switch to OFF position, then perform troubleshooting.
1 detent solenoid S06 (male) Resistance
(open circuit or defective contact)
Resistance Max. 1 z
(female) (1)
Defective boom bucket & AJSS L07 Bucket lever Voltage
3
controller
Between (27) and ground Bucket detent
20 to 30 V
operation
WA1200-6 40-449
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit
Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit40-450
Action
Failure code Bucket TILT magnet detent solenoid: ground fault
level Failure
E03 DWN8KB
q Due to ground fault in bucket TILT magnet detent solenoid power supply system, abnormal voltage
Detail of failure
exists when bucket TILT magnet detent solenoid is deenergized
Related infor-
mation

Resistance Max. 1 z
3
controller
20 to 30 V
operation
40-450 WA1200-6
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short
Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short 40-451
Action Bucket TILT magnet detent solenoid: Short circuit to power sup-
Failure code
level Failure ply line
E03 DWN8KY (Boom bucket & AJSS controller system)
q Abnormal voltage appears when no current is output to the bucket tilt magnet detent solenoid due
Detail of failure
to hot short circuit in the bucket tilt magnet detent solenoid power supply system.
Related infor-
mation

Voltage Max. 1 V
3
controller
20 to 30 V
operation
WA1200-6 40-451
Failure code [DWNAKA] NC solenoid disconnection
Failure code [DWNAKA] NC solenoid disconnection 40-452

WA1200-6
Action
Failure code Modulation NC solenoid system error
level Failure
E01 DWNAKA
Detail of failure Open circuit has occurred in the modulation NC solenoid (neutral cut solenoid) circuit
Action of con-
NC solenoid output: OFF
troller
Problem onWhen there is an open circuit
machine q Neutral cut control will not work (otherwise, no problem will appear on the machine)
Related infor-
mation
monitor

1 Defective neutral cut solenoid S06 (male) Resistance
Open circuit in wiring harness 3. Turn starting switch to ON position to perform troubleshooting.
Max. 1 z
tact of connector) HR1 (female) (1)
Resistance
Max. 1 z
ground
Work equipment control Work equipment control
L07 (female)
Defective boom bucket & AJSS lever operated (voltage) lever NEUTRAL (voltage)
3
controller Between (36) and
17–30 V Max. 1 V
ground
- Note -
Operate work equipment lever slightly (to the extent work equipment does not
move) (just enough to detect PPC pressure signals)
40-452 WA1200-6
Failure code [DWNAKB] NC solenoid short circuit
Failure code [DWNAKB] NC solenoid short circuit 40-453

Action
level Failure
E01 DWNAKB
Detail of failure Ground fault has occurred in the modulation NC solenoid (neutral cut solenoid) circuit
Action of con-
NC solenoid output: OFF
troller
Problem on When ground fault has occurred
machine q Neutral cut control will not work (otherwise, no problem will appear on the machine)
Related infor-
mation
monitor

L07 (female)
3
17–30 V Max. 1 V
ground
- Note -
WA1200-6 40-453
Failure code [DWNAKY] NC solenoid hot short
Failure code [DWNAKY] NC solenoid hot short 40-454

Action
level Failure
E01 DWNAKY
Detail of failure Hot short circuit has occurred in the modulation NC solenoid (neutral cut solenoid) circuit
Action of con-
troller
Problem on When there is a hot short circuit
machine Rising of work equipment is slow
q
Related infor-
mation
monitor

Voltage Max. 1 V
L07 (female)
3
17–30 V Max. 1 V
ground
- Note -
40-454 WA1200-6
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short

Circuit) 40-45
Action Work equipment pump solenoid valve system error (input signal
Failure code
level Failure out of range)
E03 DXA1KA (Boom bucket & AJSS controller system)
Detail of failure Open circuit or ground fault has occurred in the work equipment pump solenoid valve circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Defective work equipment pump
solenoid valve
solenoid valve
Resistance Max. 1 z
(female) (1)
Open circuit in wiring harness without turning stating switch to ON position.
3
4
WA1200-6 40-455
Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)
40-456 WA1200-6
Failure code [DXA1KY] Loader pump solenoid Relay hot short
Failure code [DXA1KY] Loader pump solenoid Relay hot short 40-457
Failure code
E03 DXA1KY (Boom bucket & AJSS controller system)
Detail of failure Hot short circuit has occurred in work equipment pump solenoid valve circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

solenoid valve
solenoid valve
Voltage Max. 1 V
3
WA1200-6 40-457
Failure code [DXA1KY] Loader pump solenoid Relay hot short
40-458 WA1200-6
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short

Circuit) 40-459
Failure code
E03 DXA1MA (Boom bucket & AJSS controller system)
Detail of failure Open circuit or ground fault has occurred in the work equipment pump solenoid valve circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

solenoid valve
solenoid valve
Resistance Max. 1 z
(female) (1)
4
WA1200-6 40-459
Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)
40-460 WA1200-6
Failure code [DXF0KA] AJSS EPC solenoid disconnection
Failure code [DXF0KA] AJSS EPC solenoid disconnection 40-461

Action
Failure code Steering source pressure EPC solenoid system error
level Failure
(Work equipment and joystick steering controller system)
E03 DXF0KA
Detail of failure Open circuit has occurred in steering source pressure control EPC solenoid circuit
Action of con-
Steering source pressure control EPC solenoid output: OFF
troller
q Steering lever response becomes dull
Problem on q Steering becomes slower
machine q Steering lever response becomes sensitive
q Steering becomes quicker
mation monitor

2. Disconnect R33 (solenoid) and connect T-adapter.
Defective steering source pres- 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
sure control EPC solenoid Check if failure code is displayed when R33 is replaced with another EPC
solenoid of the same type
(Replace with another EPC solenoid of the same type)
2. Connect T-adapter to connector L07 and each connector to R33 to be
Open circuit in wiring harness disconnected in turn.
tact of connector) Wiring harness between L07 (female) (23) and R33
(female) (2), and wiring harness between L07 Resistance Max. 1 z
(female) (26) and R33 (female) (1)
Defective work equipment and joy-
3 L07 (female) Current value
stick steering controller
(23)–(26) 600 ± 80 mA
Check on multi monitor screen
WA1200-6 40-461
Failure code [DXF0KA] AJSS EPC solenoid disconnection
40-462 WA1200-6
Failure code [DXF0KB] AJSS EPC solenoid short circuit
Failure code [DXF0KB] AJSS EPC solenoid short circuit 40-463

Action
Failure code Steering source pressure EPC solenoid system error
level Failure
(Work equipment and joystick steering controller system)
E03 DXF0KB
Detail of failure Ground fault has occurred in steering source pressure control EPC solenoid circuit
Action of con-
Steering source pressure control EPC solenoid output: OFF
troller
q Steering lever response becomes dull
Problem on q Steering becomes slower
machine q Steering lever response becomes sensitive
q Steering becomes quicker
mation monitor

2. Disconnect R33 (solenoid) and connect T-adapter.
Defective steering source pres- 3. Turn the starting switch to OFF position, then perform troubleshooting.
1
sure control EPC solenoid Check if failure code is displayed when R33 is replaced with another EPC
solenoid of the same type
(Replace with another EPC solenoid of the same type)
2. Disconnect connectors from L07 to R33 in turn and connect T-adapter.
Resistance
Min. 1 Mz
3 L07 (female) Current value
(23)–(26) 600 ± 80 mA
Check on multi monitor screen
WA1200-6 40-463
Failure code [DXF0KB] AJSS EPC solenoid short circuit
40-464 WA1200-6
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection 40-465

Action
Failure code Transmission 1st solenoid system error
level Failure
E03 DXH4KA
Detail of failure Open circuit has occurred in transmission 1st solenoid circuit
Action of con-
NEUTRAL (all ECMV outputs: OFF)
troller
Problem on
Machine cannot travel
machine
Related infor-
mation
monitor

1 Defective 1st solenoid T3 (male) Resistance
nected to T3 in turn.
(female) (1)
Resistance
Max. 1 z
(female) (2)
3 Defective transmission controller Directional selector
L04 Voltage
switch
Between (25) and ground When in NEUTRAL Max. 1 V
WA1200-6 40-465
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection
40-466 WA1200-6
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit 40-467
Action
level Failure
E03 DXH4KB
Detail of failure Ground fault has occurred in transmission 1st solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Resistance
Min. 1 Mz
L04 Voltage
switch
WA1200-6 40-467
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit
40-468 WA1200-6
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short 40-469
Action
level Failure
E03 DXH4KY
Detail of failure Hot short circuit has occurred in transmission 1st solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Voltage
Max. 1 V
L04 Voltage
switch
WA1200-6 40-469
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short
40-470 WA1200-6
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection 40-471

Action
Failure code Transmission 2nd solenoid system error
level Failure
E03 DXH5KA
Detail of failure Open circuit has occurred in transmission 2nd solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect T5 (2nd solenoid) and connect T-adapter.
1 Defective 2nd solenoid T5 (male) Resistance
nected to T5 in turn.
(female) (1)
Resistance
Max. 1 z
(female) (2)
L04 Voltage
switch
WA1200-6 40-471
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection
40-472 WA1200-6
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit 40-473
Action
level Failure
E03 DXH5KB
Detail of failure Ground fault has occurred in transmission 2nd solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Resistance
Min. 1 Mz
L04 Voltage
switch
WA1200-6 40-473
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit
40-474 WA1200-6
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short 40-475
Action
level Failure
E03 DXH5KY
Detail of failure Hot short circuit has occurred in transmission 2nd solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Voltage
Max. 1 V
L04 Voltage
switch
WA1200-6 40-475
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short
40-476 WA1200-6
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection 40-47

Action
Failure code Transmission 3rd solenoid system error
level Failure
E03 DXH6KA
Detail of failure Open circuit has occurred in transmission 3rd solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect T7 (3rd solenoid) and connect T-adapter.
1 Defective 3rd solenoid T7 (male) Resistance
2. Connect T-adapter to connector L04 and connectors to T7 to be discon-
Open circuit in wiring harness nected in turn.
Resistance Max. 1 z
(female) (1)
Wiring harness between L04 (female) (3) and T7 (female) (2) Max. 1 z
L04 Voltage
switch
WA1200-6 40-477
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection
40-478 WA1200-6
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit 40-479
Action
level Failure
E03 DXH6KB
Detail of failure Ground fault has occurred in transmission 3rd solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Resistance
Min. 1 Mz
L04 Voltage
switch
WA1200-6 40-479
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit
40-480 WA1200-6
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short 40-481
Action
level Failure
E03 DXH6KY
Detail of failure Hot short circuit has occurred in transmission 3rd solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Voltage
Max. 1 V
L04 Voltage
switch
WA1200-6 40-481
Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short
40-482 WA1200-6
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection 40-483

Action
Failure code Transmission R solenoid system error
level Failure
E03 DXH7KA
Detail of failure Open circuit has occurred in transmission R solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect T11 (R solenoid) and connect T-adapter.
1 Defective R solenoid T11 (male) Resistance
nected in turn.
(female) (1)
Resistance
Max. 1 z
(female) (2)
L04 Voltage
switch
WA1200-6 40-483
Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection
40-484 WA1200-6
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit 40-485
Action
level Failure
E03 DXH7KB
Detail of failure Ground fault has occurred in transmission R solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Resistance
Min. 1 Mz
L04 Voltage
switch
WA1200-6 40-485
Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit
40-486 WA1200-6
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short 40-487
Action
level Failure
E03 DXH7KY
Detail of failure Hot short circuit has occurred in transmission R solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Voltage
Max. 1 V
L04 Voltage
switch
WA1200-6 40-487
Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short
40-488 WA1200-6
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection 40-489

Action
Failure code Transmission F solenoid system error
level Failure
E03 DXH8KA
Detail of failure Open circuit has occurred in transmission F solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

2. Disconnect T13 (F solenoid) and connect T-adapter.
1 Defective F solenoid T13 Resistance
nected in turn.
(female) (1)
Resistance
Max. 1 z
(female) (2)
L04 Voltage
switch
WA1200-6 40-489
Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection
40-490 WA1200-6
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit 40-491
Action
level Failure
E03 DXH8KB
Detail of failure Ground fault has occurred in transmission F solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Resistance
Min. 1 Mz
L04 Voltage
switch
WA1200-6 40-491
Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit
40-492 WA1200-6
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short
Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short 40-493
Action
level Failure
E03 DXH8KY
Detail of failure Hot short circuit has occurred in transmission F solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Voltage
Max. 1 V
L04 Voltage
switch
WA1200-6 40-493
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection
Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection 40-494

Action
Failure code Transmission modulation clutch solenoid system error
level Failure
E03 DXHPKA
Detail of failure Open circuit has occurred in modulation clutch solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

Defective modulation clutch
ECMV solenoid
Max. 1 z
Resistance
Max. 1 z
(female) (1)
40-494 WA1200-6
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit
Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit 40-495
Action
Failure code Modulation clutch solenoid system error
level Failure
E03 DXHPKB
Detail of failure Ground fault has occurred in modulation clutch solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

ECMV solenoid
WA1200-6 40-495
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V
Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to

24 V 40-496
Action
Failure code Modulation clutch solenoid system error
level Failure
E03 DXHPKY
Detail of failure Hot short circuit has occurred in modulation clutch solenoid circuit
Action of con-
troller
Problem on
machine
Related infor-
mation
monitor

ECMV solenoid
Voltage Max. 1 V
40-496 WA1200-6
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction 40-497

Action
Failure code Modulation ECMV solenoid system error
level Failure
E01 DXHPMA
Detail of failure An open circuit, ground fault, or hot short circuit has occurred in the modulation ECMV solenoid circuit
Emergency spool operates
q
Action of con-
Emergency operation switch: ON
q
troller
q Process impossible (when M01 (7) side is hot short circuited)
q Driving force does not change when driving force control dial is operated.
Problem on q Tire slip control does not work.
machine q Travel speed cannot be controlled
q Machine can travel in any gear speed
Related infor-
mation
monitor

ECMV solenoid
Max. 1 z
Resistance
Max. 1 z
(female) (2)
3
4
Voltage Max. 1 V
WA1200-6 40-497
Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction
40-498 WA1200-6
Troubleshooting of electrical system (E-mode),
E-1 Remote positioner "RAISE" or "LOWER" LED does not light up
Troubleshooting of electrical system (E-mode), 40-49

E-1 Remote positioner "RAISE" or "LOWER" LED does not light up 40-49
WA1200-6
Failure Remote positioner "RAISE" or "LOWER" LED does not light up.
q Check that multi monitor operates normally.
Related information q If fuse I (II) is blown, check wiring harness between fuse and L136 (female) (1) or L138 (fe-
male) (1) for ground fault.

1. Prepare with starting switch OFF.
2. Connect T-adapters to L07 connector and each connector to be discon-
1 (wire breakage or defective con- 3. Turn the starting switch OFF, then carry out troubleshooting.
tact of connector) Between L07 (female) (8) and S12 (female) (1) Max. 1 z
Resis-
Between L07 (female) (18) and S12 (female) (3) tance Max. 1 z
2. Connect T-adapters to connector L07 and each connector to be discon-
nected in turn.
Ground fault in wiring harness 3. Turn the starting switch OFF, then carry out troubleshooting.
2
(Contact with ground circuit) Between ground and L07 (female) (8) or S12 (female)
Min. 1 Mz
(1) Resis-
Between ground and L07 (female) (18) or S12 (female) tance
Min. 1 Mz
(3)
2. Disconnect connector L07 and connect T-adapters.
3 3. Turn the starting switch OFF, then carry out troubleshooting.
Between chassis ground and each of L07 (female) (8) Resis-
Min. 1 Mz
and (18) tance
WA1200-6 40-499
E-2 Open circuit or ground fault in check lamp system
E-2 Open circuit or ground fault in check lamp system 40-50

Failure Open circuit or ground fault in check lamp system
Check lamp
Related information q Lights up: Max 1 V
q Goes out: 20 to 30 V

2. Connect T-adapters to connector V1 and each connector to be discon-
tact of connector) Between V1 (female) (14) and RA10 (female) (2) Max. 1 z
Resis-
Between V1 (female) (14) and RA11 (female) (2) tance Max. 1 z
2. Connect T-adapter to V1 connector and each connector to be disconnected
in turn.
2 3. Turn the starting switch OFF, then carry out troubleshooting.
Between V1 (female) (14) and RA10 (female) (2) Resis- Min. 1 Mz
Between V1 (female) (14) and RA11 (female) (2) tance Min. 1 Mz
3 Defective VHMS controller 3. Turn the starting switch OFF, then carry out troubleshooting.
Resis-
Between V11 (female) (14) and chassis ground Min. 1 Mz
tance
40-500 WA1200-6
E-3 Machine monitor does not operate
E-3 Machine monitor does not operate 40-501

Failure Machine monitor does not work.
Related information Check that fuse No. 10 of fuse box I is not blown.

2. Connect T-adapters to connector FC01 and each connector to be discon-
nected in turn.
3. Turn the starting switch OFF, then carry out troubleshooting.
tact of connector)
Between FC01 (female) (4) and each of FCL1 (female) Resis-
Max. 1 z
(27) and LR2 (female) (7) tance
2. Disconnect connector FC01 and connect T-adapters.
2 Defective machine monitor 3. Turn starting switch to ON position and perform troubleshooting.
Between chassis ground and each of FC01 (female) (4)
Voltage 20 to 30V
and (2)
WA1200-6 40-501
E-4 Turn signal lamp does not light up
E-4 Turn signal lamp does not light up 40-502

Failure a) Right turn signal lamp does not light up.
Related information

nected in turn.
tact of connector)
Between FC02 (female) (7) and FCL1
Resistance Max. 1 z
(female) (15)
2 Defective machine monitor Voltage switches
Right turn
Between FC02 (female) (7) and chassis between 0 V and
signal lamp:
ground 20 to 30 V
ON (voltage)
repeatedly.
Failure b) Left turn signal lamp does not light up.

Related information

nected in turn.
tact of connector)
Between FC02 (female) (16) and FCL1
Resistance Max. 1 z
(female) (14)
2 Defective machine monitor Voltage switches
Left turn sig-
Between FC02 (female) (16) and chassis between 0 V and
nal lamp: ON
ground 20 to 30 V
(voltage)
repeatedly.
40-502 WA1200-6
E-4 Turn signal lamp does not light up
WA1200-6 40-503
E-5 Defective parking lamp
E-5 Defective parking lamp 40-504

Failure a) Parking lamp does not light up.
Related information

2. Disconnect connector T18 and connect T-adapters.
Defective parking brake indicator 3. Turn the starting switch OFF, then carry out troubleshooting.
1
switch Parking brake
Between T18 (female) (1) and (2) switch: ON Max. 1 z
(resistance)
nected in turn.
Between FC04 (female) (1) and each of
FCL1 (33), FR2 (8), and T18 (female) (1)
Resistance
Between chassis ground and T18 (female)
Max. 1 z
(2), JT1 (7), or (2)
3 Defective machine monitor
Parking brake
Between FC04 (female) (1) and chassis
switch: ON 20 to 30V
ground
(voltage)
Failure b) Parking lamp does not go out.

Related information

2. Disconnect connector T18 and connect T-adapters.
Defective parking brake indicator 3. Turn the starting switch OFF, then carry out troubleshooting.
1
switch Parking brake
Between T18 (female) (1) and (2) switch: ON Min. 1 Mz
(resistance)
2
(Contact with ground circuit) 3. Turn the starting switch OFF, then carry out troubleshooting.
Between FC04 (female) (1) and each of
FCL1 (33), FR2 (8), and T18 (female) (1)
Parking brake
Between and FC04 (female) (1) and chassis
switch: OFF 0–2 V
ground
(voltage)
40-504 WA1200-6
E-5 Defective parking lamp
WA1200-6 40-505
E-6 Defective front working lamp
E-6 Defective front working lamp 40-506

Failure a) Neither pilot lamp on machine monitor nor front working lamp lights up.
Related information Check for blown-out bulbs before troubleshooting.

2. Disconnect relay L60, replace it with other normal relay, and connect
Defective front working lamp relay T-adapters.
1
(L60) 3. Turn starting switch to ON position and perform troubleshooting.
Replace with other normal relay. Lamp lights up.
2. Disconnect connectors L60, FL1, and CL1, and connect T-adapters.
Between L60 (female) (2) and fuse III (2)
(female) (1)
tact of connector)
Resistance Between L60 (female) (1) and each of
FL1 (female) (9), L60 (female) (3), and Max. 1 z
CL1 (male) (1)
Failure b) Front working lamp lights up but pilot lamp on machine monitor does not light up.

Open circuit in wiring harness 2. Disconnect connectors FC13 and L60, and connect T-adapters.
tact of connector) Between FC13 (female) (12) and L60
Resistance Max. 1 z
(female) (1)
Failure c) Pilot lamp on machine monitor lights up but front working lamp does not light up.

2. Disconnect connectors L60, C27, and C28, and connect T-adapter.
Open circuit in wiring harness 3. Turn the starting switch OFF, then carry out troubleshooting.
1 (wire breakage or defective con- Between L60 (female) (3) and each of C27
Max. 1 z
tact of connector) (female) (1) and C28 (female) (1)
Resistance
Between L60 (female) (1) and WORK3
Max. 1 z
(female) (1)
40-506 WA1200-6
E-6 Defective front working lamp
WA1200-6 40-507
E-7 Defective rear working lamp
E-7 Defective rear working lamp 40-508

Failure a) Neither pilot lamp on machine monitor nor rear working lamp lights up.

2. Disconnect relay L61, replace it with other normal relay, and connect
Defective rear working lamp relay T-adapters.
1
(L61) 3. Turn the starting switch OFF, then carry out troubleshooting.
Replace with other normal relay. Lamp lights up.
2. Disconnect connectors L61, LR11, and CL1, and connect T-adapters.
Between L61 (female) (2) and fuse III (6) Max. 1 z
tact of connector)
Resistance Between L61 (female) (1) and each of LR11
Max. 1 z
(female) (13) and LR1 (female) (13)
Failure b) Rear working lamp lights up but pilot lamp on machine monitor does not light up.

Open circuit in wiring harness 2. Disconnect connector FC03 and connect T-adapters.
tact of connector) Between FC03 (female) (12) and L61
Resistance Max. 1 z
(female) (2)
Failure c) Pilot lamp on machine monitor lights up but rear working lamp does not light up.

2. Disconnect connectors L61, GR05, and GR06, and connect T-adapters.
1 (wire breakage or defective con- Between L61 (female) (1) and each of
Max. 1 z
tact of connector) GR05 (female) (1) and GR06 (female) (1)
Resistance
Between L61 (female) (3) and each of
Max. 1 z
GR05 (female) (1) and GR06 (female) (1)
40-508 WA1200-6
E-7 Defective rear working lamp
WA1200-6 40-509
E-8 Headlamp does not light up
E-8 Headlamp does not light up 40-510

Failure Headlamp does not light up.
q Before troubleshooting, check bulb for breakage.
Related information q Check fuse III (10) for breakage.
If it is broken, check wiring harness between FC03 (female) (12) - fuse III (10) for ground fault.

2. Disconnect connectors FC3, GR03, and TURN, and connect T-adapters.
1 (wire breakage or defective con- Between FC03 (female) (12) and GR03
Max. 1 z
tact of connector) (2) (female) (5)
Resistance
Between FC03 (female) (12) and TURN
Max. 1 z
(female) (A)
40-510 WA1200-6
E-8 Headlamp does not light up
WA1200-6 40-511
E-9 Service meter does not work, or service meter works while engine is stopped.
E-9 Service meter does not work, or service meter works while engine is
stopped. 40-512
Failure a) Service meter does not work.
Related information

nected in turn.
tact of connector)
Between FC02 (female) (18) and FCL1 (female) (7) Resis-
Max. 1 z
or E04 (female) (5) tance
2 Defective machine monitor during illumi-
nance
Between FC02 (female) (18) and chassis ground Voltage
increase
adjustment
Failure b) Service meter works while engine is stopped.

Related information

nected in turn.
Hot short circuit in wiring harness 3. Turn the starting switch OFF, then carry out troubleshooting.
1
(contact with 24 V circuit) during illumi-
Between FC02 (female) (18) and FCL1 (female) nance
Resistance
(7) or E04 (female) (5) decrease
adjustment
Left turn sig-
Between FC02 (female) (18) and chassis ground nal lamp: ON 0–5 V
(voltage)
40-512 WA1200-6
E-9 Service meter does not work, or service meter works while engine is stopped.
WA1200-6 40-513
E-10 Monitor panel controller does not sound buzzer
E-10 Monitor panel controller does not sound buzzer 40-514

Failure Monitor panel controller does not sound buzzer.
Related information

2. Connect T-adapter to connector FC01and each connector to be discon-
nected in turn.
tact of connector)
Between FC01 (female) (13) and L43 (female) (2) or Resis-
Max. 1 z
between FC01 (female) (14) and L42 (female) (2) tance
2. Disconnect connectors L42 and L43 and connect T-adapters.
2 Defective machine monitor 3. Turn starting switch to ON position and perform troubleshooting.
Connect L42 (female) (1) and L43 (female) (1) to chassis ground to check
whether buzzer sounds.
3 See troubleshooting of monitor panel controller system.
40-514 WA1200-6
E-10 Monitor panel controller does not sound buzzer
WA1200-6 40-515
E-11 Defective auto-greasing system
E-11 Defective auto-greasing system 40-516

Failure a) Forced lubrication cannot work.
Related information

Open circuit in wiring harness 2. Disconnect connectors S14 and GRE1, and connect T-adapters.
tact of connector)
Between S14 (female) (6) and GRE1 (female) (1) Resistance Max. 1 z
2. Disconnect connector S14 and connect T-adapters.
Auto-greasing
Between S14 (female) (6) and chassis ground switch: ON Max 3 V
(voltage)
3 See Operation and maintenance manual, "Handling the auto-greasing system".
Failure b) Auto-greasing indicator lamp flashes rapidly (2 times/second).

Related information

Open circuit in wiring harness 2. Disconnect connectors FC02 and GRE1, and connect T-adapters.
tact of connector) Resis-
Between FC02 (female) (3) and GRE1 (female) (2) Max. 1 z
tance
2 Defective machine monitor during illu-
minance
Between FC02 (female) (3) and chassis ground Voltage increase
adjust-
ment
Failure c) Auto-greasing indicator lamp flashes slowly (1 times/second)

Related information

FC02(3) Display
L Rapid flashing (2 times/second)
Relationship between input signal
2 and display of auto-greasing indi- L Slow flashing (1 time/second)
cator lamp
H Off
H ON
40-516 WA1200-6
E-11 Defective auto-greasing system
WA1200-6 40-517
Troubleshooting of hydraulic and mechanical system (H-mode)
Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)
Troubleshooting of hydraulic and mechanical system (H-mode) 40-518

Before performing troubleshooting of work equipment hydraulic system
(how to use the multi monitor) 40-518
a Engine speed and oil pressures (work equipment pressures and PPC oil pressures) can be easily mea-
WA1200-6
sured by using the multi monitor.

a Methods for measuring the above values are shown below. There are 2 measuring methods.
q Measuring standard values by using multi monitor
..... how to get the measured data displayed on the multi monitor screen to read off
q Measuring standard values with manual Snapshot function
..... how to capture the measured data to read on a PC
Reference docu-
Item
ment page
1. Measuring standard values by using multi monitor 40-518
1) How to use multi monitor 40-519
2) Measuring PPC relief oil pressure using [Pm Clinic] 40-520
3) Measuring engine speed and work equipment relief oil pressure using [Real-time mon-
40-521
itor].
4) Measuring engine speed 40-522
2. Measuring standard values with manual Snapshot function 40-524
1) Measuring standard values using [Manual Snapshot] 40-524
2) Points to remember when using the manual Snapshot function 40-526
1. Measuring standard values by using multi monitor

a The following 3 items can be measured by using [Real-time monitor] and [Pm Clinic] functions of the
multi monitor.
q Engine speed ---- Real-time monitor [Engine] -- Engine speed display
q Work equipment relief oil pressure ---- Real-time monitor [Load meter] -- Current pressure (boom (lift arm) bot-
tom pressure) display
q PPC relief oil pressure ---- Pm Clinic menu -- PPC oil pressure display
40-518 WA1200-6
1) How to use multi monitor

Procedure for selecting to service mode and screen display
WA1200-6 40-519
2) Measuring PPC relief oil pressure using Pm Clinic item

[Pm Clinic] Sam-
Detected com-
1] On the service menu selecting screen, Page Item name pling Unit
ponents
use the [F3] or [F4] switch to select Pm time
Clinic, and press the [F6] switch. Engine control-
1/4 Engine speed 2S rpm
ler
Engine oil pres- Engine control-
1/4 2S kPa
sure ler
Engine oil tem- Engine control-
1/4 2S degC
perature ler
Engine coolant Engine control-
1/4 2S degC
temperature ler
Engine control-
ler
Blowby pres- Engine control-
2/4 2S kPa
sure ler
Engine control-
2/4 Boost pressure 2S kPa
ler
Exhaust gas Engine control-
2/4 2S degC
temperature ler
Ambient tem-
2/4 2S degC VHMS
perature
2] The Pm Clinic screen is displayed. Common rail Engine control-
Press the [F5] switch to display page 4/4. 2/4 2S MPa
pressure ler
The current working data values are Torque con-
displayed in real time. 3/4 verter oil tem- 2S degC Main moniter
When the [F3] switch is pressed, the perature
current data is held. Torque con-
3/4 verter inlet 2S MPa VHMS
pressure
Torque con-
3/4 verter outlet 2S MPa VHMS
pressure
Transmission
3/4 2S MPa VHMS
main pressure
Transmission
3/4 lubricating oil 2S MPa VHMS
pressure
Modulation Transmission
3/4 2S MPa
clutch pressure controller
Hydraulic oil
4/4 2S °C Main moniter
temperature
4/4 PPC pressure 2S MPa VHMS
Hydraulic oil Work equip-
4/4 2S MPa
a When the [F5] switch is pressed, the page pressure ment controller
S/T pump pres-
is advanced and the necessary data are 4/4 2S MPa VHMS
sure
displayed. F brake oil pres-
4/4 2S MPa VHMS
sure
R brake oil
4/4 2S MPa VHMS
pressure
40-520 WA1200-6
3) Measuring engine speed and work equipment relief oil pressure using [Real-time monitor]
WA1200-6 40-521
4) Measuring engine speed

Measuring torque converter stall speed
1] Set transmission cut-off switch (1) to OFF
and depress left brake (4) securely (make
sure that the transmission cut-off pilot
lamp is off).
2] Set transmission auto/manual shift
selector switch (3) to "ON (Manual)".
a At this time, the gear shift mode is in
"2nd".
3] Press upshift switch (6) to upshift to "3rd".
a In 2nd the machine will move because
drive force is larger than braking force.
Therefore, use 3rd in which the
braking force becomes larger than the
drive force.
4] Set forward and reverse (FNR) switch (7)
in "F" or "R".
5] Set parking brake switch (5) to the OFF
position to release the brake.
6] Measure the engine speed when the
torque converter is in the stalled condition
with the engine at full speed.
40-522 WA1200-6
Measuring hydraulic stall speed a Engine speed standard values

Relieve the boom (lift arm) cylinder or bucket Engine MODE: fixed to “AUTO” or “P”
cylinder on the extraction side with engine at (rpm)
full speed, and measure the engine speed. Standard
Testing condition value for new Repair limit
Measuring torque converter + hydraulic machine
Low idle 625 – 675 575 – 725
stall speed High idle 1,850 – 1,950 1,800 – 2,000
1] In the same way as "Measuring low idle Torque converter stall 1,800 – 2,000 1,700 – 2,000
and high idle speeds", display item Hydraulic stall 1,800 – 2,000 1,700 – 2,000
"Engine speed" on the real-time monitor Full stall 1,650 – 2,000 1,550 – 2,000
screen.
2] Set transmission cut-off switch (1) to OFF Engine MODE: fixed to “E”
(rpm)
and depress left brake (4) securely (make Standard
sure that the transmission cut-off pilot Testing condition value for new Repair limit
lamp is off). machine
3] Set transmission auto/manual shift Low idle 625 – 675 575 – 725
selector switch (3) to "ON (Manual)". High idle 1,850 – 1,950 1,800 – 2,000
a At this time, the gear shift mode is in Torque converter stall 1,750 – 1,950 1,650 – 2,000
"2nd". Hydraulic stall 1,750 – 1,950 1,650 – 2,000
Full stall 1,600 – 1,950 1,500 – 2,000
4] Press upshift switch (6) to upshift to "3rd".
a In 2nd the machine will move because
drive force is larger than braking force.
Therefore, use 3rd in which the
braking force becomes larger than the
drive force.
5] Set direction selection (FNR) switch (7) in
"F" or "R".
6] Set parking brake switch (5) to the OFF
7] Relieve the boom (lift arm) cylinder or
bucket cylinder on the extraction side with
engine at full speed and torque converter
stalled, and then measure the engine
speed.
WA1200-6 40-523
2. Measuring standard values with manual Snapshot function

1) Measurement using [Manual Snapshot]
a In addition to the above mentioned method, data can be captured and sent to a PC for anal-
ysis by using the manual Snapshot function of the multi monitor.
a See page 40-112 for points to remember when using this function.
1] Select [Snapshot] on the Service menu screen.
2] The Snapshot screen appears.

When [F6] switch is pressed, the system becomes ready to capture data.
3] Capture the data.

When "Start Snapshot?" is displayed, press [F5] to start the data capturing.
40-524 WA1200-6
4] Capturing screen
Message of Snapshot being run and the elapsed time appears on the screen.
When [F1] switch is pressed, the data capturing is aborted.
5] Capturing screen
Snapshot done message is displayed for 5 seconds.
6] The Snapshot screen appears again.
WA1200-6 40-525
2) Points to remember when using the Manual Snapshot function

1] Be careful that the data are recorded at long intervals of 10 seconds for the first 300 seconds (5
minutes). (between marks a in drawing below)
2] To obtain detailed data, start loading 300 seconds (5 minutes) after the start switch is pressed
(between marks * in drawing below).
3] See next page for data items that can be obtained by using the Manual Snapshot function.
40-526 WA1200-6
a Data captured with the Snapshot function

Magnifi- Data acquired
No. Item Unit
cation from
1 Time (SMR) h 1,000 Main monitor
2 Time (GMT) – KOMTRAX Plus
3 Eng. Speed (Engine) rpm 1 Engine controller
4 Eng. SpeedTM rpm 1 T/M controller
5 Fuel inject mm3/st 100 Engine controller
6 Rail press. MPa 10 Engine controller
7 Blowby press. kPa 10 Engine controller
8 Boost press. kPa 10 Engine controller
9 Eng. oil temp. °C 1 Engine controller
10 Eng. oil press. kPa 10 Engine controller
11 Eng. cool temp. °C 1 Engine controller
12 Eng. temp. 1278L °C 1 Engine controller
13 Eng. temp. 3456L °C 1 Engine controller
14 Eng. temp. 1278R °C 1 Engine controller
15 Eng. temp. 3456R °C 1 Engine controller
16 Accelerator pedal % 1 Engine controller
17 PPC oil press. MPa 10 KOMTRAX Plus
Work equipment
18 Hyd. oil press. MPa 10
controller
19 Hyd. oil temp. °C 1 Main monitor
Work equipment
20 Frame angle mV 1
controller
Work equipment
21 Bucket pot. 1 mV 1
controller
22 Boom bottom press. MPa 10 Main monitor
23 Boom head press. MPa 10 Main monitor
24 Boom angle deg 1 Main monitor
Work equipment
25 S/T pump press. MPa 10
controller
Work equipment
26 AJSS Lever mV 1
controller
Work equipment
27 Frame angle deg 1
controller
28 Shift indicator – T/M controller
29 T/M output shaft speed rpm 1 T/M controller
30 Vehicle speed km/h 10 T/M controller
31 T/C oil temp. °C 1 Main monitor
32 M/C output shaft speed rpm 1 T/M controller
33 M/C slip rate % 1 T/M controller
34 M/C oil press. MPa 10 T/M controller
35 F. brake charge oil press. MPa 10 KOMTRAX Plus
36 R. brake charge oil press. MPa 10 KOMTRAX Plus
37 Brake oil temp. °C 1 Main monitor
38 Brake oil press. MPa 10 T/M controller
39 Brake switch R T/M controller
40 Air temp. °C 1 KOMTRAX Plus
41 Engine mode – T/M controller
WA1200-6 40-527
Work equipment hydraulic system, general
Work equipment hydraulic system, general 40-528

a The general structure of this section is shown below.
Reference document
Item
page
Work equipment oil pressure group 40-530
Work equipment general function diagram 40-530
1. Walk-around check 40-532
1) Function diagram 40-532
2) Troubleshooting flow 40-534
3) Walk-around machine check 40-535
4) Visual check around hydraulic tank 40-535
1] Checking for looseness of hydraulic tank cap (oil stains around oil filler port) 40-535
2] Checking for missing gasket of hydraulic tank cap 40-535
3] Checking if transducer (if equipped) valve is closed 40-536
4] Checking and replacement of breather element 40-536
5] Cleaning and replacement of hydraulic oil central breather air element (if equipped) 40-536
6] Breather layout drawing 40-540
5) Checking oil level 40-542
1] Checking oil level in engine oil pan, and adding oil 40-542
2] Checking oil level in transmission, and adding oil 40-542
3] Checking oil level in hydraulic tank, and adding oil 40-543
2. Checking standard values by using KOMTRAX Plus (checking work equipment valve PPC
40-544
group)
3) Checking engine speed 40-547
RPM set ON/OFF switch 40-549
RPM set idle-up/down selector switch 40-550
3. Checking of work equipment valves 40-552
Measuring individual relief pressures of main valve and work equipment lift speed 40-555
4. Checking pump control PPC group 40-556
3) Layout of components 40-559
Layout of coin filters at both ends of ES valve 40-559
4) Differential valve layout drawing 40-560
5) How to check abnormality record of neutral cut-off solenoid valve (NC valve) 40-561
6) How to disable pump control function to obtain maximum pump delivery when failure
40-562
occurs in neutral cut-off solenoid valve (NC valve)
7) Testing and adjusting differential valve output oil pressure 40-563
8) Differential valve performance 40-566
40-528 WA1200-6
Work equipment hydraulic system, general
Reference document
Item
page
5. Checking pump control PV group 40-568
4) Testing and adjusting PV control relief valve oil pressure 40-571
6. Checking No. 1 work equipment pump, No. 2 work equipment pump, sub pump group 40-574
Layout of high-pressure line filter components 40-577
7. Checking No. 1 work equipment pump, No. 2 work equipment pump, main pump group 40-580
3) Pump CO (cut-off) performance 40-583
4) Pump checking procedure 40-585
5) Testing and adjusting work equipment pump CO (cut-off) valve oil pressure 40-586
No. 1 work equipment pump 40-586
No. 2 work equipment pump 40-588
Switch pump 40-590
8. Checking steering pump, switch pump group 40-592
WA1200-6 40-529
Work equipment oil pressure group

Work equipment general function diagram 40-530
[Troubleshooting method for work equipment oil pressure group]
1. Perform troubleshooting by judging the groups of related components in sequence.
40-530 WA1200-6
2. The subject group is shown in hatched lines, and the troubleshooting flow is shown. (in following pages)
3. Pages that should be referred to proceed with the work are given in each troubleshooting flow in the
following pages.
WA1200-6 40-531

a Check portions shown with hatched lines in the drawing.
40-532 WA1200-6
WA1200-6 40-533

Contents of work
(1) Walk-around check ... Around machine/around hydraulic tank/oil level check
Refer to page A: 40-535

B: 40-535, 538
D: 40-542
E: 40-544
40-534 WA1200-6

Check for oil leaks from hydraulic piping around and inside the machine.

1] Checking for looseness of hydraulic tank cap (oil stains around oil filler port)
2] Checking for missing gasket of hydraulic tank cap
WA1200-6 40-535
3] Checking if transducer (if equipped) valve is closed (see next page)
4] Checking and replacement of breather element (see next page)
5] Cleaning and replacement of hydraulic oil central breather air element (if equipped)
3] Checking if transducer (if equipped) valve is closed
40-536 WA1200-6
WA1200-6 40-537
4] Checking and replacement of breather element

Check the appearance of breather and filter element.
40-538 WA1200-6
WA1200-6 40-539
6] Breather layout drawing
40-540 WA1200-6
WA1200-6 40-541
5) Checking oil level 40-542 2] Checking oil level in transmission, and adding
1] Checking oil level in engine oil pan, and add- oil
ing oil k Immediately after the engine is stopped, its
k Immediately after the engine is stopped, its parts and oil are still very hot. Therefore, wait
parts and oil is still be very hot and you may until their temperature drops before starting
be scalded. Wait until their temperature the work.
drops before starting the work. a Before starting the engine, make sure that
a When checking with the engine stopped, wait the oil level is within upper A or between up-
for at least 15 minutes after stopping the en- per A and lower B of sight gauge (G).
gine, and check the oil level. 1. Start the engine and run it at low idle.
a When checking, park the machine on a level 2. Remove the cap of oil filler port (F).
ground.
1. Open the inspection window at the rear left side
of the machine.
2. Remove dipstick (1) and wipe off the oil by using
a cloth.
3. Reinsert dipstick (1) fully in the pipe until a click
is heard, and remove it .
4. If the oil level is between lines H and L on dipstick
(1), it is at the correct level. If the oil level is below
line L, add oil through oil filler port (2).
3. When the oil is warmed up (approx. 40 to 60 °C),

check the oil level at sight gauge (G).
If the oil level is within the range of lower B of
sight gauge (G), it is at the correct level.
4. If the oil level is not within the range of lower B of
sight gauge (G), add oil through oil filler port (F).
5. If the oil level is above H, loosen drain plug (1) to

drain the excessive oil. Do not allow oil drain to
the ground. Collect the oil in a container by using
a vinyl tube.
Check the oil level again by using the dipstick.
5. If the oil level is above lower B of sight gauge (G),

remove drain plug (1), and loosen drain valve (2)
to drain the excessive oil, and then check the oil
level again.
6. If the oil is at the correct level, tighten oil filler cap

(2) securely and close the inspection window.
40-542 WA1200-6
6. When the oil level is correct, tighten the cap. 2. If the oil level is below sight gauge (1), open the
inspection cover above the steps and add oil
through oil filler port (6). The oil level can be
checked by using dipstick (1) when adding oil. If
the oil level is near line H on the dipstick, it is at
the correct level.
3] Checking oil level in hydraulic tank, and add-

ing oil
parts and oil is still be very hot and you may
be scalded. Wait until their temperature
drops before starting the work.
k When removing the oil filler cap, turn it slow-
ly to release the internal pressure, then re-
move it.
1. Lower bucket to the ground and stop the engine.
Wait for approx. 5 minutes before checking oil
level. Oil level should be seen in sight gauge (1),
the oil level is correct.
a If the oil level is above the proper level, stop

the engine. After the hydraulic oil drops,
drain excessive oil through the drain plug.
Excessive oil may damage the oil circuit and
cause the oil to spurt out.
WA1200-6 40-543
2. Checking standard values by using KOMTRAX Plus (checking work equipment valve PPC group) 40-54
40-544 WA1200-6
WA1200-6 40-545

Contents of work
(1) Measure the engine speed and PPC relief oil pressure by using KOMTRAX Plus.
(2) Measure the PPC differential pressure at both ends of work equipment valve using a Bourdon
tube.
Results
(1) If the reading is in the specified range, it is normal.
(2) If abnormal, take additional measurements by following the troubleshooting flow to locate the
faulty part and take actions.
Refer to page A: 40-521, 522

B: 40-519, 520
C: 40-563
D: 40-565, 566
E: 40-565, 566
40-546 WA1200-6

Contents of work
(1) Measure the engine speed. If abnormal, check the fuel filter and the accelerator pedal.
(2) If still abnormal, ask Cummins for repair.

B: 40-521, 522
C: 40-549, 550
WA1200-6 40-547
Standard value
(1) (Engine speed, work equipment speed)
Standard value for new machine
Fixed to “AUTO” or “P” Fixed to “E”
Engine speed Low idle 625 – 675 625 – 675
(rpm) High idle 1,850 – 1,950 1,850 – 1,950
Hydraulic relief 1,800 – 2,000 1,750 – 1,950
At torque converter stall 1,800 – 2,000 1,750 – 1,950
Full stall 1,650 – 2,000 1,600 – 1,950
Work equipment speed Boom (lift arm) RAISE time 12.5 ± 0.5 13.7 ± 0.5
(at high idle) Boom (lift arm) LOWER time 5.0 ± 0.5 5.0 ± 0.5
(sec) Ground tilting time 2.3 ± 0.3 2.5 ± 0.3
No load Dumping time 3.7 ± 0.3 3.7 ± 0.3
(2) Stall speed

Standard value for new
Repair limit
machine
Fixed to Fixed to
Fixed to “E” Fixed to “E”
“AUTO” or “P” “AUTO” or “P”
q Coolant:
At torque converter
Within operating 1,800 – 2,000 1,750 – 1,950 1,700 – 2,000 1,650 – 2,000
stall range
Torque converter oil
Engine speed
q
temperature: 60 to
Hydraulic stall 80 °C rpm 1,800 – 2,000 1,750 – 1,950 1,700 – 2,000 1,650 – 2,000
At torque converter perature: 45 to
stall 55 °C
q Gear shift lever: F4 1,650 – 2,000 1,600 – 1,950 1,550 – 2,000 1,500 – 2,000
and
Hydraulic stall or R4
40-548 WA1200-6
RPM set ON/OFF switch (1) 40-549

This switch turns on and off the power supply to the RPM set system.
Position (a): power supply to system ON
Indicator lamp lights up.
Position (b): power supply to system OFF
Indicator lamp goes out.
(R.H. switch panel)
Supplementary explanation 40-549

q RPM set ON/OFF switch (1) only turns on and off the power supply to the RPM set system. To set the
engine speed, RPM set idle-up/down selector switch (2) is used.
q This is a seesaw switch and it should not be pressed carelessly.
WA1200-6 40-549
RPM set idle-up/down selector switch (2) 40-5 0

a When RPM set ON/OFF switch (1) or engine starting switch is tuned OFF, the idle-up/down speed memory
is cleared. To set the speed again, repeat the procedure from the beginning.
a If the right brake pedal is depressed for waiting for a dump truck, etc. when the RPM set idle-up/down se-
lector switch (2) is used, the engine speed lowers from the memorized speed to low idle. The engine speed
returns to the set speed when portion (d) of the switch is pressed again.
a To operate this switch, make sure that RPM set ON/OFF switch (1) is in the ON position. When ON, indi-
cator lamp lights up.
This switch is used for maintaining a desired engine speed.

(R.H. switch panel)
Position (c): q Setting engine speed with the RPM set switch is
This is used when setting the engine speed or in- advantageous because excessive lowering in
creasing the set speed. engine speed can be avoided during work using
q Using the accelerator pedal the accelerator pedal. The engine response will
Depress the accelerator pedal and press be better and the cycle time of work can be re-
portion (c) of switch at the desired engine duced.
speed. The speed is stored and set. q Since the travel speed can be maintained con-
q Using the RPM set idle-up/down switch stant while travelling for load-and-carry opera-
When portion (c) of switch is pressed and tion, the operator's fatigue can be reduced.
held down for longer than 0.5 sec. the engine q If resetting the engine speed to a desired speed
speed increases. Release the switch at the without using portion (d) of the RPM set
desired speed. The new speed is stored and idle-up/down selector switch, depress the right
set. brake pedal to cancel the set speed, and then
depress the accelerator pedal to increase the
Position (d): engine speed. Depress setting side (c) of the
This is used when decreasing the set the engine switch at the desired speed. The new speed is
speed, or recover the RPM set switch after it has stored and set.
been cancelled.
q Using the RPM set up/down switch
When portion (d) of switch is pressed and
held down for longer than 0.5 sec. the engine
speed decreases. Release the switch at the
desired speed. The new speed is stored and
set.
Supplementary explanation 40-5 0
40-550 WA1200-6
WA1200-6 40-551
3. Checking of work equipment valves 40-5 2

1) Function diagram 40-5 2
40-552 WA1200-6
WA1200-6 40-553
2) Troubleshooting flow 40-5 4

Contents of work
(1) Measure the engine speed and work equipment relief oil pressure by using KOMTRAX Plus.
(2) Measure the relief set pressure at each of the 3 work equipment valves. Adjust or replace parts
if any abnormality is found.
Refer to page A: 40-555 F: 40-555

B: 40-555 G: 40-563, 564
C: 40-519 H: 40-563, 564
D: 40-521 I: 40-555
E: 40-523 J: 40-555
40-554 WA1200-6
Measuring individual relief pressures of main valve and work equipment lift speed 40-5 5
1. Remove the work equipment valve cover.
2. Measure the relief pressure and work equipment
speed on the No. 1 valve.
Disconnect PPC circuit for other than the No. 1
valve.
3. Similarly, measure the relief pressure and work
equipment speed on the No. 2 valve.
valve.
4. Similarly, measure the relief pressure and work
equipment speed on the No. 3 valve.
valve.
a Bleed air from the circuit each time after the PPC
circuits are disassembled and reassembled to
install the oil pressure gauge.
a Testing condition
Measure for boom (lift arm) RAISE (no load)
Standard value
Reference
All valves
No. 1 valve (left) No. 2 valve (cen- No. 3 valve
No. 1 valve
only ter) only (right) only
No. 2 valve
No. 3 valve
Main relief oil pressure (at stroke end) MPa 30 to 32 30 to 32 30 to 32 30 to 32
Boom (lift arm) RAISE speed (at no load) sec 12 to 24 41 to 44 33 to 35 41 to 44
WA1200-6 40-555
4. Checking pump control PPC group 40-5 6

40-556 WA1200-6
WA1200-6 40-557

Contents of work
(1) Measure the engine speed by using KOMTRAX Plus.
(2) Measure the differential pressure between both ends of No. 1 work equipment pump ES valve
using a Bourdon tube.
(3) If abnormal, check the VHMS error record, disable the NC valve function, measure differential
pressure at differential valve, and replace parts.
Refer to page A: 40-519 F: 40-562

B: 40-521, 522 G: 40-563, 564
C: 40-561 H: 40-565, 566
D: 40-559 I: 40-566
E: 40-562
40-558 WA1200-6
3) Layout of components 40-5 9
WA1200-6 40-559
4) Differential valve layout drawing 40-560
40-560 WA1200-6
5) How to check abnormality record of neutral cut-off solenoid valve (NC valve) 40-561
a If a short circuit occurs in the NC valve, the pump delivery is kept at the minimum.
a Short circuit in the NC valve can be confirmed by checking the abnormality record on the VHMS.
Check if failure code [DWNAKA, DWNAKB, or DWNAKY: Modulation NC solenoid system error] is displayed
in the abnormality record according to the following procedure.
1] Select [Failure History (abnormality record)] on the SERVICE MENU SELECT screen.
2] The [FAILURE HISTORY(abnormality record)] screen is displayed.

a Abnormality records are displayed in reverse chronological order.
WA1200-6 40-561
6) How to disable pump control function to obtain maximum pump delivery when neutral cut-off sole-
noid valve (NC valve) fails 40-562
a If failure code [DWNAKZ] is displayed, pump delivery can be kept at maximum by removing the
neutral cut-off solenoid valve (NC valve).
1. Remove neutral cut-off solenoid valve (NC valve) (1), and install plug (m20 x 1.5).
2. Remove union (5), piping (7), elbow (8), and then install plugs (M14 x 1.5) to connections (B) and (C).
*Put the circuit in a condition that ports (A) and (B) are always connected.
40-562 WA1200-6
7) Testing and adjusting differential valve output oil pressure 40-563

a Testing tools
1
C {60 kg/cm2})
2 799-101-5160 q Nipple
4 799-261-1311 q Adapter

k Park the machine on a level ground, apply Testing 40-563
the parking brake, lower the bucket to the 1. Stop the engine.
ground, and reserve a safe area. k Operate the work equipment control lever
k Chock the wheels to prevent the machine to release the pressure from the work
from moving. equipment PPC accumulator.
k Stop the engine, then loosen the oil filler cap 2. Disconnect hose (5) from P1 port and hose (6)
to release the pressure in the hydraulic tank. from P2 port of the ES valve. Install adapters C4
and nipples C2 and reconnect hoses (5) and (6).
q Differential valve output oil pressure can be
checked by measuring the input pressure at P1
and P2 ports of the ES valve.
a ES valve (1) is installed to No. 2 work equip-
ment pump (2).
a Measure the oil pressure from A port of NC

valve (3) to P1 port of ES valve (1) and the oil
pressure from PB port of differential valve (4)
to P2 port of ES valve (1). Obtain and check
the difference in pressure between P1 and
P2 ports.
3. Connect oil pressure gauge C1 (6 MPa

WA1200-6 40-563
40-564 WA1200-6
Reference Adjusting 40-565

Operating conditions for NC valve (to reduce 1. If the pressure difference is out of the standard
piston pump delivery) value, replace the differential valve or follow the
q Gear speed: F3 steps below to bring it in line with the standard
q Travel speed: Min. 10 km/h value by adjusting the valve.
q Work equipment control levers: Neutral 1) Stop the engine.
k Operate the work equipment control
4. Measure oil pressure at P1 and P2 ports with the lever to release the pressure from the
engine running at low idle (650 rpm) and at high work equipment PPC accumulator.
idle (1,900 rpm). Check whether the differences
in pressure between Port 1 and Port 2 meet the 2) Remove differential valve assembly (4).
standard values. a Clean any oil, dirt, etc. off the valve and
piping.
q Standard values for pressure difference be-
tween P1 and P2 ports
Oil pressure (MPa Differential
{kg/cm2}) pressure
Engine speed (MPa
P1 port P2 port
{kg/cm2})
Low idle 3.7 to 3.9 3.7 to 3.9
0
(625 – 675 rpm) {38 to 40} {38 to 40}
High idle 4.9 to 5.5 4.3 to 4.9 0.5 to 0.6
(1,850 – 1,950 rpm) {50 to 56} {44 to 50} {5 to 6}
3) Remove plug (7), and add or remove shims

(8).
a When adjusting by using shims for the dif-
ferential valve, set it with the plug facing
up.
a Shim part No.: 427 - 62 - 11710 (t 0.1)
: 427-62-11720(t0.2)
: 427-62-11730(t0.5)
a The set pressure will increase by adding
shims, and decrease by removing shims.
4) Install plug (7) and then install differential

valve assembly (4).
WA1200-6 40-565
8) Differential valve performance 40-56
a Performance of the differential valve is shown below for reference.

(It is difficult to accurately measure by using equipment in the field.)
a If the PPC system performance is questionable, replace the differential valve with a new one.
40-566 WA1200-6
WA1200-6 40-567
5. Checking pump control PV group 40-568

40-568 WA1200-6
WA1200-6 40-569

Contents of work
(2) Measure the PV relief pressure with a Bourdon tube
(3) If abnormal, adjust PV relief set pressure or replace parts, or replace PV line filter.
Refer to page A: 40-519 C: 40-569, 571

B: 40-521, 522 D: 40-569, 571, 572
40-570 WA1200-6
3) Layout of components 40-571 4) Testing and adjusting PV control relief valve

oil pressure 40-571
a Testing tools
1
C {60 kg/cm2})
2 799-101-5160 q Nipple
3 790-261-1311 q Nipple

from moving.
q The PV control relief valve controls the servo
valve maximum pressure of each work equip-
ment pump.
PV valve set pressure: 2.9 MPa {30 kg/cm2}
WA1200-6 40-571
Testing 40-572 Adjusting 40-572

1. Stop the engine. a If the oil pressure is not within the standard value
k Operate the work equipment control lever range, adjust the PV control relief valve within
to release the pressure from the work the standard value.
equipment PPC accumulator. q Loosen lock nut (4) of the PV control valve and
2. Remove plug (2) (PT1/8) from block (1), install turn adjustment screw (5) to adjust the pressure.
nipple C2, and then connect oil pressure gauge a Turn the adjustment screw clockwise to in-
C1(6 MPa {60 kg/cm2}). crease the set pressure, and turn it counter-
ment screw:
Per turn: 1.0 MPa {10.4 kg/cm2}
3 Locknut:
29.4 to 39.2 Nm {3 to 4 kgm}
3. Start the engine and measure the oil pressure

while running the engine at high idle (2,050 rpm)
to check if the pressure is within the standard
value range.
q Standard value: 2.8 to 3.2 MPa
{28 to 32 kg/cm2}
40-572 WA1200-6
WA1200-6 40-573
6. Checking loader pump, No. 1 work equipment pump, No. 2 work equipment pump, sub pump group40-574
40-574 WA1200-6
WA1200-6 40-575

Contents of work
(2) Check the high-pressure line filter. If metallic powder (material worn off from pump) is found,
replace pump.
(3) On No. 2 valve only, measure work equipment relief pressure and boom (lift arm) RAISE speed
with no load on bucket.
Refer to page A: 40-577 G: 40-596, 597, 598

B: 40-519 H: 40-587
C: 40-521, 522 I: 40-555
D: 40-578 J: 40-589
E: 40-586 K: 40-588, 589
F: 40-585 L: 40-588, 589
40-576 WA1200-6

Layout of high-pressure line filter components
WA1200-6 40-577
40-578 WA1200-6
WA1200-6 40-579
7. Checking No. 1 work equipment pump, No. 2 work equipment pump, main pump group 40-580
40-580 WA1200-6
WA1200-6 40-581

Contents of work
replace pump.
Refer to page A: 40-519, 520, 521 D: 40-555

B: 40-577 E: 40-596, 597, 598
C: 40-596, 597, 598 F: 40-586
40-582 WA1200-6
3) Pump CO (cut-off) performance 40-583

a The pump detects the self pressure. If the pump delivery pressure increases, it decreases the pump de-
livery.
WA1200-6 40-583
40-584 WA1200-6

(1) Measure boom (lift arm) RAISE speed with no load -- use a stopwatch
(2) Press in CO valve screw fully -- to create a pseudo delivery pressure over 280 kg/cm2 (load and pump
delivery minimum) o Measure boom (lift arm) RAISE speed with no load -- use a stopwatch
(3) Finally, restore the CO valve output pressure characteristics.
CO + (NC)
a For the adjustment procedure, see page 40-585, 586 (NC valve not functioning).
WA1200-6 40-585
5) Testing and adjusting work equipment pump CO (cut-off) valve oil pressure 40-586
a Testing tools No. 1 work equipment pump 40-586
Symbol Part No. Part name 1. Preparation
Oil pressure gauge kit (analog) 1) Remove the rear side pump delivery pres-
(Pressure gauge: 6 MPa sure pickup plug (7) on the No. 1 work equip-
799-101-5002
1 {60 kg/cm2}, 40 MPa ment pump.
{400 kg/cm 2}) 2) Install joint C3 and nipple C2 of the oil pres-
C
790-261-1204 Oil pressure gauge kit (digital) sure gauge kit, and connect oil pressure
2 799-101-5160 q Nipple
gauge C1(40 MPa {400 kg/cm2}) to nipple
3 790-301-1271 q Joint
4 790-261-1311 q Adapter C2.
3) Remove cover (1a) at the top of No. 1 work
equipment pump (1).
from moving.
a To test the oil pressures of the work equipment

pump CO valves, measure the delivery pres-
sures of No. 1 work equipment pump (1) and No.
2 work equipment pump (2), and the output pres-
sures of CO valves (4), (5), and (6) installed on
each pump at ports on the servo valve side.
40-586 WA1200-6

plug (9) on rear servo valve (8) of No. 1 work
equipment pump (1).
5) Install joint C3 and nipple C2 of the oil pres-
sure gauge kit, and connect oil pressure
gauge C1 (6 MPa {60 kg/cm2}) to nipple C2.
3) Turn in the screw until the CO valve output

pressure reading on gauge (B) meets the
standard value when the reading on gauge
(A) reaches 27.5 MPa {280 kg/cm2} as the
boom (lift arm) lever on the work equipment
is slowly moved to RAISE to increase the No.
1 work equipment pump delivery pressure.
0.37 MPa {3.8 kg/cm2}

a Increase the engine speed if the No.1
2. Testing CO valve oil pressure

1) Adjust the pressures by loosening lock nut
(10) for CO+NC valve (4) and turning adjust-
ment screw (11) by using a screwdriver.
2) With the engine running at low idle (650 rpm)
and the bucket slowly moved to TILT end,
read the No.1 work equipment pump delivery
pressure and the CO valve output pressure
on oil pressure gauges (A) and (B).
A: Pump delivery pressure gauge
C1(40 MPa {400 kg/cm2})
B: CO valve output pressure gauge
C1(6 MPa {60 kg/cm2})
WA1200-6 40-587
3. Adjusting CO valve pressure No. 2 work equipment pump 40-58

1) Adjust the pressures by loosening lock nut 1. Preparation
(10) for CO+NC valve (4) and turning adjust- 1) Remove the front side pump delivery pres-
ment screw (11) by using a screwdriver. sure pickup plug (11) on the No. 2 pump.
a To raise the cut-off, turn adjustment 2) Install joint C3 and nipple C2 of the oil pres-
screw (11) clockwise. To lower the sure gauge kit, and connect oil pressure
cut-off, turn it counterclockwise. Repeat gauge C1 (40 MPa {400 kg/cm2}) to nipple
the procedure until the correct set pres- C2.
sure is obtained.
{41.3 kg/cm2}.
3) Disconnect hose (14) from elbow (15) on

front servo valve (13) of the No. 2 pump.
4) Install adapter C4 and nipple C2 of the oil
pressure gauge kit to elbow (15) and connect
hose (14).
5) Install oil pressure gauge C1 (6 MPa

joint and nipple of the oil pressure gauge kit
and restore the machine.
40-588 WA1200-6
2. Testing CO valve oil pressure 3. Adjusting CO valve pressure

1) With the engine running at low idle (650 rpm) 1) Adjust by loosening lock nut (16) for CO+NC
and the bucket slowly moved to TILT end, valve (5) and turning adjustment screw (17)
read the No.2 work equipment pump delivery by using a screwdriver.
pressure and the CO valve output pressure a To raise the cut-off, turn adjustment
on oil pressure gauges (A) and (B). screw (17) clockwise. To lower the
A: Pump delivery pressure gauge cut-off, turn it counterclockwise. Repeat
C1 (40 MPa {400 kg/cm2}) the procedure until the correct set pres-
B: CO valve output pressure gauge sure is obtained.
C1 (6 MPa {60 kg/cm2})
{41.3 kg/cm2}.
2) Check to ensure that the CO valve output

pressure reading on gauge (B) meets the
standard value when the reading on gauge
(A) reaches 25.5 MPa {260 kg/cm2} as the
bucket lever on the work equipment is slowly
moved to TILT to increase the No. 2 work
equipment pump delivery pressure.
0.74 MPa {7.6 kg/cm2}

a Increase the engine speed if the No. 2

WA1200-6 40-589
Switch pump 40-590 2. Testing CO valve oil pressure

a Do not operate steering. 1) With the engine running at low idle (650 rpm)
1. Preparation and the bucket slowly moved to TILT end,
1) Remove the front side pump delivery pres- read the switch pump delivery pressure and
sure pickup plug (18) on the switch pump. the CO valve output pressure on oil pressure
2) Install joint C3 and nipple C2 of the oil pres- gauges (A) and (B).
sure gauge kit, and connect oil pressure A: Pump delivery pressure gauge
gauge C1 (40 MPa {400 kg/cm2}) to nipple C1 (40 MPa {400 kg/cm2})
C2. B: CO valve output pressure gauge
C1 (6 MPa {60 kg/cm2})

plug (20) on servo valve (19) at the front side 2) Check to ensure that the CO valve output
of the switch pump. pressure reading on gauge (B) meets the
4) Install joint C3 and nipple C2 of the oil pres- standard value when the reading on gauge
sure gauge kit, and connect oil pressure (A) reaches 29.4 MPa {300 kg/cm2} as the
gauge C1 (6 MPa {60 kg/cm2}) to nipple C2. bucket lever on the work equipment is slowly
moved to TILT to increase the switch pump
delivery pressure.
0.37 MPa {3.8 kg/cm2}

a Raise the engine speed if the switch
pump delivery pressure does not reach
29.4 MPa {300 kg/cm2}.
40-590 WA1200-6
3. Adjusting CO valve pressure

1) Adjust the pressures by loosening lock nut
(21) for CO+NC valve (6) and turning adjust-
ment screw (22) by using a screwdriver.
a To raise the cut-off, turn adjustment
screw (22) clockwise. To lower the
cut-off, turn it counterclockwise. Repeat
the procedure until the correct set pres-
sure is obtained.
will increase the switch pump delivery
pressure by 4.1 MPa {41.3 kg/cm2}.

WA1200-6 40-591
8. Checking steering pump, switch pump group 40-592

40-592 WA1200-6
WA1200-6 40-593

Contents of work
replace pump.
Refer to page A: 40-519 F: 40-577

B: 40-521, 522 G: 40-555
C: 40-587, 588, 589 H: 40-586
D: 40-555 I: 40-586
E: 40-596, 597, 598 J: 40-585
40-594 WA1200-6
Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)
Before performing troubleshooting of steering oil pressure system (how

to use the multi monitor) 40-595
a Engine speed and oil pressures (work equipment pressures and PPC oil pressures) can be easily mea-
sured by using the multi monitor.
a Methods for measuring the above values are shown below. There are 2 measuring methods.
q Measuring standard values by using multi monitor
..... how to get the measured data displayed on the multi monitor screen to read off
q Measuring standard values by using manual Snapshot function
..... how to capture the measured data to read on a PC
Reference docu-
Item
ment page
1. Measuring standard values by using multi monitor 40-595
1) How to use multi monitor 40-596
2) Measuring PPC relief pressure using [Pm Clinic] 40-597
3) Measuring engine speed and work equipment relief oil pressure using [Real-time moni-
40-598
tor].
4) Measuring engine speed 40-599
2. Measuring standard values with manual Snapshot function 40-599
1) Measuring standard values using [Manual Snapshot] 40-599
2) Points to remember when using the manual Snapshot function 40-602
3) Measuring input current to EPC valve using [Real-time monitor]. 40-603
4) Measuring steering pump outlet pressure using [Pm Clinic] 40-605
5) Measuring potentiometer output voltage using [Real-time monitor]. 40-606
1. Measuring standard values by using multi monitor

a The following 3 items can be measured by using [Real-time monitor] and [Pm Clinic] functions of the
multi monitor.
q Engine speed ---- Real-time monitor [Engine] -- Engine speed display
q Work equipment relief pressure ---- Real-time monitor [Work equipment] -- Current pressure (boom (lift arm)
bottom pressure) display
q PPC relief oil pressure ---- Pm Clinic menu -- PPC oil pressure display
WA1200-6 40-595
1) How to use multi monitor

Displaying SERVICE MENU SELECT screen
40-596 WA1200-6
2) Measuring PPC relief oil pressure using [Pm Clinic]

1] Select Pm Clinic on the SERVICE MENU SELECT screen.
2] The Pm Clinic screen is displayed.
a When F5 is pressed, the page is advanced and the necessary data are displayed.
Pm Clinic items Torque con-
KOMTRAX
Pag Sampling Detected com- 3/4 verter outlet 2S MPa
Item name Unit Plus controller
e time ponents pressure
Engine control- Transmission KOMTRAX
1/4 Engine speed 2S rpm 3/4 2S MPa
ler main pressure Plus controller
Engine oil pres- Engine control- Transmission
1/4 2S kPa KOMTRAX
sure ler 3/4 lubricating oil 2S MPa
Engine oil tem- Engine control- Plus controller
pressure
1/4 2S degC
perature ler Modulation Transmission
Engine coolant Engine control- 3/4 2S MPa
1/4 2S degC clutch pressure controller
temperature ler Hydraulic oil
Engine control- 4/4 2S °C Main moniter
2/4 Engine speed 2S rpm temperature
ler KOMTRAX
4/4 PPC pressure 2S MPa
Blowby pres- Engine control- Plus controller
2/4 2S kPa
sure ler Hydraulic oil Work equip-
4/4 2S MPa
Engine control- pressure ment controller
ler S/T pump pres- KOMTRAX
4/4 2S MPa
Exhaust gas Engine control- sure Plus controller
2/4 2S degC
temperature ler F brake oil pres- KOMTRAX
Ambient tem- KOMTRAX 4/4 2S MPa
sure Plus controller
2/4 2S degC
perature Plus controller R brake oil KOMTRAX
Common rail Engine control- 4/4 2S MPa
2/4 2S MPa pressure Plus controller
pressure ler
Torque con-
3/4 verter oil tem- 2S degC Main moniter
perature
Torque con-
KOMTRAX
3/4 verter inlet 2S MPa
Plus controller
pressure
WA1200-6 40-597
3) Measuring engine speed and work equipment relief oil pressure using [Real-time monitor]
1] Select real-time monitor on the SERVICE MENU SELECT screen.
40-598 WA1200-6
4) Measuring engine speed Measuring torque converter + hydraulic

Measuring torque converter stall speed stall speed
1] Set transmission cut-off switch (1) to OFF 1] In the same way as "Measuring low idle
and depress left brake (4) securely (make and high idle speeds", display item
sure that the transmission cut-off pilot "Engine speed" on the real-time monitor
lamp is off). screen.
2] Set transmission auto/manual shift 2] Set transmission cut-off switch (1) to OFF
selector switch (3) to "ON (Manual)". and depress left brake (4) securely (make
a At this time, the gear shift mode is in sure that transmission cut-off pilot lamp
"2nd". (2) is off).
3] Press upshift switch (6) to upshift to "3rd". 3] Set transmission auto/manual shift
a In 2nd the machine will move because selector switch (3) to "ON (Manual)".
drive force is larger than braking force. a At this time, the gear shift mode is in
Therefore, use 3rd in which the "2nd".
braking force becomes larger than the 4] Press the upshift switch to upshift to "3rd".
drive force. a In 2nd the machine will move because
4] Set forward and reverse (FNR) switch (7) drive force is larger than braking force.
in "F" or "R". Therefore, use 3rd in which the
5] Set parking brake switch (5) to the OFF braking force becomes larger than the
position to release the brake. drive force.
6] Measure the engine speed when the 5] Set the forward and reverse (FNR) switch
torque converter is in the stalled condition in "F" or "R".
with the engine at full speed. 6] Set parking brake switch (5) to the OFF
7] Relieve the boom (lift arm) cylinder or
bucket cylinder on the extraction side with
engine at full speed and torque converter
stalled, and then measure the engine
speed.
a Engine speed standard values

Engine MODE: fixed to “AUTO” or “P”
(rpm)
Standard
machine
Low idle 625 – 675 575 – 725
High idle 1,850 – 1,950 1,800 – 2,000
Measuring hydraulic stall speed Torque converter stall 1,800 – 2,000 1,700 – 2,000
Relieve the boom (lift arm) cylinder or bucket Hydraulic stall 1,800 – 2,000 1,700 – 2,000
Full stall 1,650 – 2,000 1,550 – 2,000
cylinder on the extraction side with engine at
full speed, and measure the engine speed. Engine MODE: fixed to “E”
(rpm)
Standard
machine
Low idle 625 – 675 575 – 725
High idle 1,850 – 1,950 1,800 – 2,000
Torque converter stall 1,750 – 1,950 1,650 – 2,000
Hydraulic stall 1,750 – 1,950 1,650 – 2,000
Full stall 1,600 – 1,950 1,500 – 2,000
2. Measuring standard values with manual a In addition to the above mentioned

Snapshot function method, data can be captured and sent
1) Measurement using [Manual Snapshot] to a PC for analysis by using the man-
ual Snapshot function of the multi
monitor.
a See page 20-1001-2-7 for points to re-
member when using this function.
WA1200-6 40-599
1] Select [Snapshot] on the SERVICE

MENU SELECT screen.
2] The Snapshot screen appears.
3] Capture the data.
40-600 WA1200-6
4] Capturing screen
5] Capturing screen
6] The Snapshot screen appears again.
WA1200-6 40-601
2) Points to remember when using the Manual Snapshot function

1] Be careful that the data are recorded at long intervals of 10 seconds for the first 300 seconds (5
minutes). (between marks a in drawing below)
2] To obtain detailed data, start capturing 300 seconds (5 minutes) after the start switch is pressed
(between marks * in drawing below).
3] See next page for data items that can be obtained by using the Manual Snapshot function.
40-602 WA1200-6
3) Measuring input current to EPC valve using [Real-time monitor].

a Select Real-time monitor on the SERVICE MENU SELECT screen.
1] Select "Real-time monitor" on the SERVICE MENU SELECT screen and press [F6] switch.
2] Select "Work equipment" on the "REAL TIME MONITOR" screen and press [F6] switch.
3] Press [F5] switch to display page 6/9.
WA1200-6 40-603

Displayed page Signal name Unit Remarks
1/9 Software No. --- ---
1/9 Software application version --- ---
1/9 Software application data version --- ---
2/9 Boom (lift arm) Raise EPC Current 1 1 mA 0 to 1,000
2/9 Boom (lift arm) Lower EPC Current 1 1 mA 0 to 1,000
3/9 Bucket Tilt EPC Current 1 1 mA 0 to 1,000
3/9 Bucket Dump EPC Current 1 1 mA 0 to 1,000
4/9 Lever potentiometer voltage boom (lift arm) 1 0.01 V 0.00 to 5.00
4/9 Lever potentiometer voltage bucket 1 0.01 V 0.00 to 5.00
5/9 Boom (lift arm) angle 0.1 deg -60 to +60
5/9 Boom (lift arm) angle 0.01 V 0.00 to 5.00
5/9 Boom (lift arm) lever operation frequency – 0 to 256,000
5/9 Bucket lever operation frequency – 0 to 256,000
5/9 Pump delivery 1 cc 0 to 500
6/9 AJSS lever operation angle 0.1 deg -60 to +60
6/9 AJSS lever potentiometer voltage 0.01 V 0.00 to 5.00
6/9 AJSS frame potentiometer voltage 0.01 V 0.00 to 5.00
6/9 AJSS EPC Current 1 mA 0 to 1,000
7/9 Loader pump pressure 0.01 MPa 0 and 50
7/9 Loader pump pressure 0.001 V 0 to 5
7/9 Boom (lift arm) bottom pressure 0.01 MPa 0 and 50
7/9 Boom (lift arm) bottom pressure 0.001 V 0 to 5
7/9 AJSS S/T deviation angle 0.1 deg 0 to +120
7/9 Digging-in-progress flag 1: ON (digging) 0: OFF ---
8/9, 9/9 Input/Output signal 1: ON 0: OFF(OPEN) ---
40-604 WA1200-6
4) Measuring steering pump outlet pressure Pm Clinic item

using [Pm Clinic] Sam-
Detected com-
a Select Pm Clinic on the SERVICE Page Item name pling Unit
ponents
MENU SELECT screen. time
Engine control-
ler
Engine oil pres- Engine control-
1/4 2S kPa
sure ler
Engine oil tem- Engine control-
1/4 2S degC
perature ler
Engine coolant Engine control-
1/4 2S degC
temperature ler
Engine control-
ler
Blowby pres- Engine control-
2/4 2S kPa
sure ler
Engine control-
ler
Exhaust gas Engine control-
2/4 2S degC
temperature ler
Ambient tem- KOMTRAX
2/4 2S degC
perature Plus controller
Common rail Engine control-
2/4 2S MPa
pressure ler
Torque con-
3/4 verter oil tem- 2S degC Main moniter
perature
Torque con-
KOMTRAX
3/4 verter inlet 2S MPa
Plus controller
pressure
Torque con-
KOMTRAX
3/4 verter outlet 2S MPa
Plus controller
pressure
Transmission KOMTRAX
3/4 2S MPa
main pressure Plus controller
Transmission
KOMTRAX
3/4 lubricating oil 2S MPa
Plus controller
pressure
Modulation Transmission
3/4 2S MPa
clutch pressure controller
Hydraulic oil
4/4 2S °C Main moniter
temperature
KOMTRAX
4/4 PPC pressure 2S MPa
Plus controller
Hydraulic oil Work equip-
4/4 2S MPa
pressure ment controller
S/T pump pres- KOMTRAX
4/4 2S MPa
F brake oil pres- KOMTRAX
4/4 2S MPa
R brake oil KOMTRAX
4/4 2S MPa
pressure Plus controller
WA1200-6 40-605
5) Measuring potentiometer output voltage using [Real-time monitor]

a Select real-time monitor on the SERVICE MENU SELECT screen.
1] Select "Real-time monitor" on the SERVICE MENU SELECT screen and press [F6] switch.
2] Select "Work equipment" on the "REAL TIME MONITOR" screen and press [F6] switch.
3] Press [F5] switch to display page 6/9.
40-606 WA1200-6

Displayed page Signal name Unit Remarks
1/9 Software No. --- ---
1/9 Software application version --- ---
1/9 Software application data version --- ---
5/9 Boom (lift arm) angle 0.01 V 0.00 to 5.00
5/9 Boom (lift arm) lever operation frequency --- 0 to 256,000
5/9 Bucket lever operation frequency --- 0 to 256,000
5/9 Pump delivery 1 cc 0 to 500
6/9 AJSS lever operation angle 0.1 deg -60 to +60
6/9 AJSS lever potentiometer voltage 0.01 V 0.00 to 5.00
6/9 AJSS frame potentiometer voltage 0.01 V 0.00 to 5.00
6/9 AJSS EPC Current 1 mA 0 to 1,000
7/9 Loader pump pressure 0.01 MPa 0 and 50
7/9 Loader pump pressure 0.001 V 0 to 5
7/9 Boom (lift arm) bottom pressure 0.01 MPa 0 and 50
7/9 Boom (lift arm) bottom pressure 0.001 V 0 to 5
7/9 AJSS S/T deviation angle 0.1 deg 0 to +120
7/9 Digging-in-progress flag 1: ON (digging) 0: OFF ---
8/9, 9/9 Input/Output signal 1: ON 0: OFF(OPEN) ---
WA1200-6 40-607
Checking steering related standard values
Checking steering related standard values 40-608

(Lock-to-lock steering time is too long, shock is large, steering effort abnormal)
(1) Standard value
Category
Standard value
Item Testing condition Unit for new Repair limit
machine
q Engine stopped
q Measure on lever knob (at 149 mm
Steering lever
Play from lever pivot point) mm Max. 8 Max. 16

q Hold the rotation of the steering ro-
tary valve.
q Flat, level, straight, dry, and paved 13.7 ± 5.0 23.5
Steering
road {1.4 ± 0.5} {2.4}

Operating angle degree 80 ± 8 Max. 90
Max. 6.5 Max. 7.5
Operating time
Low idle q Engine started 5.7 ± 0.5 5.7 ± 0.5

sec.
55 °C 4.9 ± 0.4 4.9 ± 0.4
High idle
q Left lock to right lock Max. 5.6 Max. 6.5
31.36 31.36
Steering relief pressure MPa (+0.98/-0.29) (+0.98/-1.27)
Hydraulic oil temperature: 45 to
Steering
q
{320 (+10/-3)} {320 (+10/-13)}
55 °C {kg/cm2 3.72
q Engine speed: At full speed } 3.72 (+0.19/0)
Orbit-roll output pressure (+0.39/-0.19)
{38 (+2/0)}
{38 (+4/-2)}
(2) If abnormal shocks are reported, confirm the conditions under which they occur.
Engine speed
Lo Mid Hi
F1
While travel-
F2
ling
F3
No load
During work
Loaded
At beginning of steer-
Response ing
At end of steering
40-608 WA1200-6
Steering oil pressure system, general
Steering oil pressure system, general 40-609

Reference
Item document
page
Steering oil pressure group 40-610
Steering general function diagram 40-610
1] Checking for looseness of hydraulic tank cap (oil stains around oil filler port) 40-614
2] Checking for missing gasket of hydraulic tank cap 40-614
5] Cleaning and replacement of hydraulic oil central breather air element (if equipped) 40-616
1] Checking oil level in engine oil pan, and adding oil 40-620
2] Checking oil level in transmission, and adding oil 40-620
3] Checking oil level in hydraulic tank, and adding oil 40-621
6) Measuring steering lock-to-lock operating time 40-621
2. Checking standard values by using KOMTRAX Plus (checking steering pilot circuit group and linkages) 40-622
RPM set ON/OFF switch 40-626
RPM set idle-up/down selector switch 40-627
4) Adjusting steering stopper bolt 40-628
5) Adjusting steering follow-up linkage 40-628
6) Checking steering EPC valve 40-632
7) Testing and adjusting steering surge cut valve oil pressure 40-634
8) Testing and adjusting steering main relief valve oil pressure 40-636
3. Checking steering pump (sub), switch pump (sub), steering valve (left) group 40-638
4. Checking steering pump (main), switch pump (main), steering valve (right) group 40-640
3) AJSS neutral interlock function 40-642
5) Checking right and left steering valves individually 40-646
6) Steering pump (main) CO valve characteristics 40-648
WA1200-6 40-609
Steering oil pressure group
Steering oil pressure group 40-610

Steering general function diagram 40-610
[Troubleshooting method for steering oil pressure group] 40-610
1. Perform troubleshooting by judging the groups of related components in sequence.
2. The subject group is shown in hatched lines, and the troubleshooting flow is shown. (in following pages)
3. Pages that should be referred to proceed with the work are given in each troubleshooting flow in the
following pages.
40-610 WA1200-6
WA1200-6 40-611

40-612 WA1200-6

Contents of work
(1) Walk-around check ... Around machine/around hydraulic tank/oil level check
(2) Measure steering lock-to-lock operating time by using a stopwatch.

B: 40-614, 615
C: 40-620, 621
D: 40-621
E: 40-622
WA1200-6 40-613


1] Checking for looseness of hydraulic tank cap (oil stains around oil filler port)
2] Checking for missing gasket of hydraulic tank cap
40-614 WA1200-6
3] Checking if transducer (if equipped) valve is closed (see next page)

4] Checking and replacement of breather element (see next page)
5] Cleaning and replacement of hydraulic oil central breather air element (if equipped)
3] Checking if transducer (if equipped) valve is

closed
WA1200-6 40-615
a Opening and closing directions of valve
40-616 WA1200-6

WA1200-6 40-617
40-618 WA1200-6
WA1200-6 40-619

1] Checking oil level in engine oil pan, and add- 2] Checking oil level in transmission, and adding
ing oil oil
k Immediately after the engine is stopped, its k Immediately after the engine is stopped, its
parts and oil is still be very hot and you may parts and oil are still very hot. Therefore, wait
be scalded. Wait until their temperature until their temperature drops before starting
drops before starting the work. the work.
a When checking with the engine stopped, wait a Before starting the engine, make sure that
for at least 15 minutes after stopping the en- the oil level is within upper A or between up-
gine, and check the oil level. per A and lower B of sight gauge (G).
a When checking, park the machine on a level 1. Run the engine at low idle.
ground. 2. Remove the cap of oil filler port (F).
1. Open the inspection window at the rear left side
of the machine.
2. Remove dipstick (1) and wipe off the oil with a
cloth.
3. Reinsert dipstick (1) fully in the pipe until a click
is heard, and remove it.
4. If the oil level is between lines H and L on
dipstick (1), it is at the correct level. If the oil level
is below line L, add oil through oil filler port (2).
3. When the oil is warmed up (approx. 40 to 60 °C),

check the oil level at sight gauge (G).
If the oil level is within the range of lower B of
sight gauge (G), it is at the correct level.
4. If the oil level is not within the range of lower B of
sight gauge (G), add oil through oil filler port (F).
5. If the oil level is above H, loosen drain plug (1) to

drain the excessive oil. Do not allow oil drain to
the ground. Collect the oil in a container by using
a vinyl tube.
Check the oil level again by using the dipstick.
6. If the oil is at the correct level, tighten oil filler cap

(2) securely and close the inspection window.
40-620 WA1200-6
5. If the oil level is above lower B of sight gauge 2. If the oil level is below sight gauge (1), open the
(G), remove drain plug (1), and loosen drain inspection cover above the steps and add oil
valve (2) to drain the excessive oil, and then through oil filler port (6). The oil level can be
check the oil level again. checked by using dipstick (1) when adding oil. If
6. When the oil level is correct, tighten the cap. the oil level is near line H on the dipstick, it is at
the correct level.
3] Checking oil level in hydraulic tank, and add-

ing oil
parts and oil is still be very hot and you may
be scalded. Wait until their temperature
drops before starting the work.
k When removing the oil filler cap, turn it slow-
ly to release the internal pressure, then re-
move it.
1. Lower bucket to the ground and stop the engine.
Wait for approx. 5 minutes before checking oil
level. Oil level should be seen in sight gauge (1).
6) Measuring steering lock-to-lock operating

time 40-621
Measurement condition
q Engine started
Operating time
Item Standard value Repair limit
for new machine
Low idle 5.7 ± 0.5 5.7 ± 0.5
High idle 4.9 ± 0.4 4.9 ± 0.4
a If the oil level is above the proper level,
stop the engine. After the hydraulic oil
drops, drain excessive oil through the
drain plug. Excessive oil may damage the
oil circuit and cause the oil to spurt out.
WA1200-6 40-621
2. Checking standard values by using KOMTRAX Plus (checking steering pilot circuit group and link-
ages) 40-62
40-622 WA1200-6

Contents of work
(1) Measure the engine speed and PPC relief oil pressure by using KOMTRAX Plus.
Refer to page A: 40-619 F: 40-629

B: 40-622, 623 G: 40-632
C: 40-638 H: 40-632, 633
D: 40-637 I: 40-638
E: 40-643
WA1200-6 40-623

Contents of work
(1) Measure the engine speed. If abnormal, check the fuel filter and the accelerator pedal.
(2) If still abnormal, ask Cummins for repair.
Refer to page A: 40-619, 620, 621, 622

B: 40-626, 627
40-624 WA1200-6
Standard value
(1) (Engine speed, work equipment speed)
Standard value for new machine
Engine MODE: fixed to Engine MODE: fixed to
“AUTO” or “P” “E”
Engine speed Low idle 625 – 675 625 – 675
(rpm) High idle 1,850 – 1,950 1,850 – 1,950
Hydraulic relief 1,800 – 2,000 1,750 – 1,950
At torque converter stall 1,800 – 2,000 1,750 – 1,950
Full stall 1,650 – 2,000 1,600 –1 ,950
Work equipment speed Boom (lift arm) RAISE time 12.5 ± 0.5 13.7 ± 0.5
(at high idle) Boom (lift arm) LOWER time 5.0 ± 0.5 5.0 ± 0.5
(sec) Ground tilting time 2.3 ± 0.3 2.5 ± 0.3
No load Dumping time 3.7 ± 0.3 3.7 ± 0.3
(2) Stall speed

Engine MODE: fixed to
Engine MODE: fixed to “E”
“AUTO” or “P”
Engine Engine
Engine Engine
MODE: fixed MODE: fixed
MODE: fixed MODE: fixed
to “AUTO” or to “AUTO” or
to “E” to “E”
“P” “P”
At torque converter q Coolant:

1,800 – 2,000 1,750 – 1,950 1,700 – 2,000 1,650 – 2,000
stall Within operating
range
Engine speed
q Torque converter oil

temperature: 60 –
Hydraulic stall rpm 1,800 – 2,000 1,750 – 1,950 1,700 – 2,000 1,650 – 2,000
80 °C
At torque converter perature: 45 – 55 °C
stall q Gear shift lever: F4 1,650 – 2,000 1,600 – 1,950 1,550 – 2,000 1,500 – 2,000
and or R4
Hydraulic stall
WA1200-6 40-625
RPM set ON/OFF switch (1) 40-626

This switch turns on and off the power supply to the RPM set system.
Position (a): power supply to system ON
Indicator lamp lights up.
Position (b): power supply to system OFF
Indicator lamp goes out.
Supplementary explanation 40-626

q RPM set ON/OFF switch (1) only turns on and off
the power supply to the RPM set system. To set
the engine speed, RPM set idle-up/down selec-
tor switch (2) is used.
q This is a seesaw switch and it should not be
pressed carelessly.
40-626 WA1200-6
RPM set idle-up/down selector switch (2) 40-627

a When RPM set ON/OFF switch (1) or engine starting switch is tuned OFF, the idle-up/down speed memory
is cleared. To set the speed again, repeat the procedure from the beginning.
a If the right brake pedal is depressed for waiting for a dump truck, etc. when the RPM set idle-up/down se-
lector switch (2) is used, the engine speed lowers from the memorized speed to low idle. The engine speed
returns to the set speed when portion (d) of the switch is pressed again.
a To operate this switch, make sure that RPM set ON/OFF switch is in the ON position. When ON, indicator
lamp lights up.
This switch is used for maintaining a desired engine speed.
Position (c): Supplementary explanation 40-627

This is used when setting the engine speed or in- q Setting engine speed with the RPM set switch is
creasing the set speed. advantageous because excessive lowering in
q Using the accelerator pedal engine speed can be avoided during work using
Depress the accelerator pedal and press the accelerator pedal. The engine response will
portion (c) of switch at the desired engine be better and the cycle time of work can be re-
speed. The speed is stored and set. duced.
q Using the RPM set idle-up/down switch q Since the travel speed can be maintained con-
stant while travelling for load-and-carry opera-
When portion (c) of switch is pressed and tion, the operator's fatigue can be reduced.
held down for longer than 0.5 sec. the engine q If resetting the engine speed to a desired speed
speed increases. Release the switch at the without using portion (d) of the RPM set
desired speed. The new speed is stored and idle-up/down selector switch, depress the right
set. brake pedal to cancel the set speed, and then
Position (d): depress the accelerator pedal to increase the
This is used when decreasing the set the engine engine speed. Depress setting side (c) of the
speed, or recover the RPM set switch after it has switch at the desired speed. The new speed is
been cancelled. stored and set.
q Using the RPM set up/down switch
When portion (d) of switch is pressed and
held down for longer than 0.5 sec. the engine
speed decreases. Release the switch at the
desired speed. The new speed is stored and
set.
WA1200-6 40-627
4) Adjusting steering stopper bolt 40-628 5) Adjusting steering follow-up linkage 40-628
k Be sure to follow "Safety precautions to fol- k Be sure to follow "Safety precautions to fol-
low before starting work". low before starting work".
1. With the engine running at low idle, steer to the
right or left. If clearance (a) between frame end Adjusting 40-628
stopper (2) of front frame (1) and rear frame (3) 1. Move the frame lock bar to the "LOCK" position
is out of the specified range, adjust it in the and set the machine in the straight travel posi-
following procedure. tion.
a Clearance (a): 37 to 40 mm

to the specified length.
1) Loosen lock nut (4) and turn steering angle a Specified length L: 342 mm
adjustment bolt (5) to meet clearance (a) to
the standard value.
k Withe engine running at low idle, slow-
ly operate the joystick steering lever.
k Use care in this operation so that your
body or arm are not caught between
the front and rear frames.
2) Start and run the engine at low idle. Slowly
steer to full right or left, and make sure that
the clearance (a) between frame end stopper
(2) of front frame (1) and rear frame (3) is
within the standard value range.
a Fasten with a screw at center of the ob-
long hole.
3) When clearance adjustment is complete,
tighten lock nut (4) of adjustment bolt (5).
3 Locknut:
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
a Notes for connectors

The connectors for the frame angle and lever
angle potentiometers (56B-06-11630) are
Deutsche connectors (08192-13810).
40-628 WA1200-6
3. In this condition, measure the voltage at frame Adjusting installed position of potentiometer
angle potentiometer (2) and lever angle potenti- (work in pair) 40-629
ometer (4). a The installed position of the potentiometer can
a Voltage when potentiometer is in neutral po- be adjusted while watching the multi monitor dis-
sition: 2.5 ± 0.3 V play screen.
4. If the voltage is not 2.5 ± 0.3 V, loosen mounting
screws (3) and (5) of potentiometers (2) and (4), 1. Display the "SERVICE MENU SELECT display
and then turn each potentiometer to adjust the screen" of the service mode. Use the [F3] or [F4]
voltage. switch to select the function and the [F6] switch
a For the adjustment procedure, see"Adjusting to select "Real-time monitor".
2. Select "Work equipment controller" on the

"REAL TIME MONITOR" display screen and
press the [F6] switch. Then, the work equipment
controller item detailed screen appears.
3. Press [F5] switch to display page 6/9. Check the

value of the "S/T lever potentiometer" or "Articu-
lating angle" and adjust the installed position of
the potentiometer to meet the standard range.
WA1200-6 40-629
Offset angle automatic correction procedure for

lever angle and frame angle potentiometers 40-630
1. Display the "SERVICE MENU SELECT"o"
Adjustment menu "o" AJSS "o" AJSS Neutral
Position Adjustment" on the multi monitor.
a Lever angle potentiometer adjustment proce-

dure
Turning the potentiometer results in the output
voltage being varied in the range 0 to 5 V. Adjust
the installed positions of the upper and lower
potentiometers so that the voltage is 2.5 ± 0.3 V
at the neutral position.
2. Place the machine body and the AJSS lever in

the straight-ahead position.
40-630 WA1200-6
3. Operate the machine body as instructed on the After sending the signal, the adjustment current
screen and press [F6]. This sends a set signal to value is updated according to a signal from the
the work equipment controller. work equipment controller.
A message appears according to the command A change of the numeric value is displayed
(setting completed or setting failed) from the according to the work equipment controller. The
work equipment controller. multi monitor is not concerned with changes in
When setting is completed: "Setting Completed" the numeric value through button operations.
When setting is not completed: "Setting failed" If the [F1] switch is pressed, the screen returns
Until receiving a command: "Setting" to the adjustment menu (2) AJSS screen.
Pressing [F6] sends a set signal to the work

5. Pressing [F6] displays the table pattern number

according to the information from the work
4. Pressing [F6] displays the adjustment current "---" is displayed for the number until the infor-
value according to the information from the work mation is received first after the screen transi-
equipment controller. tion.
" ---" is displayed for the value until the informa- Pressing [F6] switch sends an AJSS oil pressure
tion is received first after the screen transition. command table pattern change signal to the
Pressing [F3] sends an UP signal to the work work equipment controller.
equipment controller. After sending the signal, the pattern number is
After sending the signal, the adjustment current updated according to a signal from the work
value is updated according to a signal from the equipment controller.
work equipment controller. A change of the numeric value is displayed
A change of the numeric value is displayed according to the work equipment controller. The
according to the work equipment controller. The multi monitor is not concerned with changes in
multi monitor is not concerned with changes in the numeric value through button operations.
the numeric value through button operations. If the [F1] switch is pressed, the screen returns
Pressing [F4] sends a DOWN signal to the work to the adjustment menu (2) AJSS screen.
WA1200-6 40-631
6) Checking steering EPC valve 40-632
Testing 40-632
frame lock bars and chock the wheels to pre-
tank, then operate the steering wheel two or
sure in the piping.
1. Remove oil pressure switch (3) from nipple (2) of
rotary valve (1) and install an oil pressure gauge.
6. The main monitor outputs the command to the

multi monitor for moving to this screen at the 2. With the engine running at low idle and the
abnormal end, but the multi monitor (KOMTRAX steering lock lever in LOCK position, move the
Plus) performs processing after moving. steering lever slowly to right and left at near the
If the [F5] switch is pressed after the message is neutral position and then read the oil pressure
confirmed, the adjustment menu (2) AJSS when it is at the minimum. If the pressure is out
screen appears. of the standard value range, replace EPC valve
When the communication error with the (4).
controller continues for 0.5 second or more a EPC valve set pressure: (steering lever at
during the adjustment, the screen returns to
neutral) 0.9 to 1.1 MPa {9 to 11 kg/cm2})
SERVICE MENU SELECT screen without
a EPC valve minimum pressure: (steering le-
moving to the abnormal end screen.
ver steered) 0.49 to 0.64 MPa {4.8 to
6.3 kg/cm2})
40-632 WA1200-6
WA1200-6 40-633
7) Testing and adjusting steering surge cut valve oil pressure 40-634
a Testing tools
Sym-
Part No. Part name
bol
1
C {600 kg/cm2})
2 799-101-5160 q Nipple
5 799-203-2440 Nipple
Testing condition
2) When measuring the right steering valve oil
the parking brake, lower the bucket to the pressure, remove plug (4) from tube (3)
ground, and reserve a safe area. between the steering pump and steering
valve, install nipples C5 and C2, and then
from moving. connect oil pressure gauge C1 (60 MPa
frame lock bars.
sure in the piping.
suring points.
a An oil pressure sensor (2) is installed on the left
steering valve.
Testing 40-634
steering valve. 2. Loosen lock nut (6) on steering main relief valve
a Since the right and left steering valve pres- (5), and screw in the adjustment screw (7) half a
sures are merged at the outlet side of the turn.
steering valve, right and left pressures can- a Ensure that only surge cut valve (8) is al-
not be measured separately at the outlet lowed to operate.
side. q Steering main relief valve set pressure:
1) When measuring the left steering valve oil 31.0 to 31.9 MPa {316 to 325 kg/cm2}
pressure, remove steering oil pressure q Surge cut valve set pressure:
sensor (2) from tube (1) between the steering 33.3 to 34.3 MPa {340 to 350 kg/cm2}
40-634 WA1200-6
Adjusting 40-635
a If the surge cut valve (8) set pressure is not cor-
rect, adjust following the steps below.
3. Start and run the engine at low idle ( 650 rpm).

Tilt the steering lever to left or right, and measure
the oil pressure when the surge cut valve is actu-
ated. k Stop the engine before adjusting the surge
q Surge cut valve set pressure: cut valve.
33.3 to 34.3 MPa {340 to 350 kg/cm2} 1. Loosen lock nut (9) for the surge cut valve and
4. After measuring or adjusting the surge cut valve, turn adjustment screw (10) to adjust the pres-
loosen adjustment screw (7) on the steering sure.
main relief valve half a turn, tighten lock nut (6) a Turn the adjustment screw clockwise to in-
and adjust the steering main relief valve. crease the set pressure and turn it counter-
ment screw
Per turn: Approx. 17.8 MPa {181 kg/cm2}
2. Do not perform any adjustment if the surge cut

valve set pressure cannot be measured.
a After adjustment of the surge cut valve, ad-
just the main relief valve.
a After testing, bleed air from the circuit and
check the oil level.
WA1200-6 40-635
8) Testing and adjusting steering main relief valve oil pressure 40-636
a Testing tools
Sym-
Part No. Part name
bol
1
C {600 kg/cm2})
2 799-101-5160 q Nipple
5 799-203-2440 Nipple
Testing condition
2) When measuring the right steering valve oil
the parking brake, lower the bucket to the pressure, remove plug (4) from tube (3)
ground, and reserve a safe area. between the steering pump and steering
valve, install nipples C5 and C2, and then
from moving. install oil pressure gauge C1 (60 MPa
frame lock bars.
sure in the piping.
suring points.
Testing 40-636
1. Steering main relief valve oil pressure must be
steering valve.
a Since the right and left steering valve pres-
sures are merged at the outlet side of the 2. Start the engine and run at high idle (engine
steering valve, right and left pressures can- speed: 2,050 rpm). Measure the oil pressure
not be measured separately at the outlet when the steering lever is moved to the right or
side. left and the main relief valve is actuated.
1) When measuring the left steering valve oil q Main relief valve set pressure:
pressure, remove steering oil pressure 31.0 to 31.9 MPa {316 to 325 kg/cm2}
sensor (2) from tube (1) between the steering
40-636 WA1200-6
Adjusting 40-637
a If the set pressure of main relief valve (5) is not
correct, adjust the main relief valve according to
k Stop the engine before adjusting the main re-

lief valve.
1. Loosen lock nut (6) of the main relief valve and

crease the set pressure and turn it counter-
ment screw
Per turn: Approx. 17.8 MPa {181 kg/cm2}
3 Locknut:
75 to 85 Nm {7.7 to 8.7 kgm}
2. Do not perform any adjustment if the main relief

valve set pressure cannot be measured accu-
rately.
WA1200-6 40-637
3. Checking steering pump (sub), switch pump (sub), steering valve (left) group 40-638
40-638 WA1200-6

Contents of work
q Troubleshooting of steering pump (sub), switch pump (sub), steering valve (left) group
(1) Remove the high-pressure line filter and check for abnormal metallic powder.
(2) Actuate the steering valve (left) separately and measure the steering relief oil pressure and
lock-to-lock steering time.
(3) Tighten the adjustment screw to create a pseudo pump maximum load condition (minimum
delivery), and measure the steering relief oil pressure and lock-to-lock steering time.
(4) Restore the adjustment screw.

B: 40-645
C: 40-637
D: 40-621, 622
E: 40-644
WA1200-6 40-639
4. Checking steering pump (main), switch pump (main), steering valve (right) group 40-640
40-640 WA1200-6

Contents of work
q Troubleshooting steering pump (main), switch pump (main), steering valve (right) group
(1) Remove the high-pressure line filter and check for abnormal metallic powder.
(2) Actuate the steering valve (right) separately and measure the steering relief oil pressure and
lock-to-lock steering time.
(3) Tighten the CO valve adjustment screw to create a pseudo pump maximum load condition
(minimum delivery), and measure the steering relief oil pressure and lock-to-lock steering time.
(4) Restore the CO valve adjustment screw.

B: 40-636
C: 40-643
D: 40-637
E: 40-644
WA1200-6 40-641
3) AJSS neutral interlock function 40-642

1. The engine does not start if the joystick steering lever is not in the NEUTRAL position.
In AJSS, the engine start signal is refused and starting the engine is prohibited by turning the neutral safety
relay on when the joystick steering lever is in a position other than neutral (deviation angle between lever
steered angle and the operated angle of the machine frame detected by the potentiometer is 6 deg. or
more), to prevent sudden turn of the machine immediately when the engine is started.
2. When the engine is running, the steering is available if the steering lock lever is set to FREE posi-
tion while the joystick steering lever is moved to a position other than neutral.
If the steering lock lever is in the LOCK position while the joystick steering lever is in a position other than
neutral and the engine is running, there is a possibility that the machine turns immediately when the
steering lock lever is moved to FREE position, so the caution buzzer sounds in order to give the operator
a warning.
3. When the engine is running, the directional slector switch will not operate if the steering lock lever
is in the LOCK position. The switch is activated when the lock lever is moved to FREE position.
Since the machine does not turn when the steering is locked, the transmission controller prohibits forward
and reverse travel of the machine. Therefore, when the directional selector switch on the joystick steering
knob is in a position other than neutral while the steering is locked, the caution buzzer sounds to give the
operator a warning because the machine may move forward or reverse immediately when the steering is
unlocked.
40-642 WA1200-6
WA1200-6 40-643
40-644 WA1200-6
WA1200-6 40-645
5) Checking right and left steering valves individually 40-646
40-646 WA1200-6
WA1200-6 40-647
6) Steering pump (main) CO valve characteristics 40-648

q The pump detects the self pressure. If the pump delivery pressure increases, it decreases the pump de-
livery.
40-648 WA1200-6

(1) Measure lock-to-lock steering time with no load -- use a stopwatch
(2) Screw in CO valve screw fully -- to create a pseudo delivery pressure 280 kg/cm2 or more (load, pump
delivery minimum) o Measure lock-to-lock steering time with maximum load -- use a stopwatch
(3) Finally, restore the CO valve output pressure characteristics.
CO + (NC)
a For the adjustment procedure, see page 40-585, 586
WA1200-6 40-649
Brake oil pressure system, general
Brake oil pressure system, general 40-650

Reference docu-
Item
ment page
Brake oil pressure group 40-651
Brake system circuit diagram 40-651
Brake function system diagram 40-654
Layout of components 40-655
4) Visual check around brake oil tank 40-669
1] Checking for looseness of brake oil tank cap (oil stains around oil filler port) 40-669
2] Checking if element is a genuine part 40-669
6) Checking strainer 40-674
2. Checking for performance deterioration by using KOMTRAX Plus (hydraulics section) 40-675
3) Warning display on multi monitor 40-679
1] Front brake oil pressure too low (during operation) 40-679
2] Rear brake oil pressure too low (during operation) 40-679
3] Brake oil level too low (during operation) 40-679
4] Front and rear brake oil pressure too low (at engine start) 40-680
5] Brake oil level too low (before engine start) 40-680
3. Checking for internal leaks in components such as valves, accumulators (oil leaks, etc.) 40-681
3) Brake related components layout drawing 40-686
4) Checking of accumulator nitrogen gas pressure and procedure for charging accumulator with
40-688
nitrogen gas
5) Explanation of brake pump outlet pressure 40-693
6) Measuring accumulator charge cut-in and cut-out pressures 40-697
7) Checking for brake accumulator oil pressure leakage 40-699
40-650 WA1200-6
Brake oil pressure group
Brake oil pressure group 40-651

Brake system circuit diagram 40-651
WA1200-6 40-651
40-652 WA1200-6
Brake function system diagram 40-653

a Relation between the hydraulic components and electrical components that consist the brake system are
shown.
WA1200-6 40-653
40-654 WA1200-6
Layout of components 40-65

a For part number and part names, see the parts book.
Transmission Accumulator
Accumulator circuit
WA1200-6 40-655
Accumulator charge valve
Front brake circuit
Accumulator (bracket)
Rear brake circuit
40-656 WA1200-6
Floor circuit 1/3
WA1200-6 40-657
Floor circuit 2/3 Floor circuit 3/3
40-658 WA1200-6
Pump circuit Suction circuit 1/2
WA1200-6 40-659
Suction circuit 2/2 Parking circuit
40-660 WA1200-6
Brake oil tank and related Brake piping drain circuit
WA1200-6 40-661
Slack adjuster 42C-43-17202 Brake valve single 421-43-27100
40-662 WA1200-6
Brake valve tandem 421-43-17101
WA1200-6 40-663
40-664 WA1200-6
1. Walk-around check 40-6 5

a For the function diagram, see the next page.
q Perform a walk-around check of the entire machine, and check the * marked areas around the brake tank
and the brake charge pump outlet side strainer.
a For the contents of the work, see the troubleshooting flow.
WA1200-6 40-665
Function diagram 40-6 6
40-666 WA1200-6
WA1200-6 40-667

Contents of work
(1) Checking around machine and around brake tank
(2) Checking brake oil level and refilling
(3) Check of brake pump outlet line strainer
Refer to page A: 40-669 F: 40-669

B: 40-669, 670 G: 40-671
C: 40-674 H: 40-669
D: 40-674
E: 40-679
40-668 WA1200-6
3) Walk-around machine check 40-6 9

4) Visual check around brake oil tank 40-6 9

1] Checking for looseness of brake oil tank cap
(oil stains around oil filler port) 2] Checking if element is a genuine part
3] Checking if transducer (if equipped) valve is

closed
WA1200-6 40-669
a Opening and closing directions of valve
40-670 WA1200-6

WA1200-6 40-671
40-672 WA1200-6
WA1200-6 40-673
5) Checking oil level 40-674 6) Checking strainer 40-674

Checking brake oil level in tank and refilling a Check the charge pump outlet side strainer, and
k When refilling the brake oil tank, be sure to replace the following items if abnormal metallic
use the recommended genuine oil. powder is found.
q Brake pump
1. Check gauge (1) for brake cooling and gauge (2) q Brake element
for brake on the side of the brake oil tanks, q Brake oil
located near the rear frame center pin at the left
side of the machine.
There are two brake oil tanks. Tank (A) at the
outside of machine is for brake cooling oil, and
tank (B) at the inside of machine is for brake oil.
Check that the oil level in the tanks are at the
following positions.
Oil level in tank (A) for brake cooling oil:
between Hi and Low level of gauge (1)
Oil level in tank (B) for brake oil:
between Hi and Low level of gauge (2)
a Bring the accumulator to the fully charged
condition (charge for 2 minutes by running
engine at low idle).
2. If the oil level is too low, open the cover on top of

the left side of the platform, open cap (3) of the
tank short of oil, and add oil.
a If the oil level is too low, check for leaks from
brake piping besides adding oil to the tank
short of oil.
40-674 WA1200-6
2. Checking for performance deterioration by using KOMTRAX Plus (hydraulics section) 40-675
q Check for performance deterioration of brake charge pump and accumulator charge valve by using
KOMTRAX Plus(Locations marked with a)
WA1200-6 40-675
40-676 WA1200-6
WA1200-6 40-677

Contents of work
(1) Measuring engine speed
(2) Measure the accumulator charge cut-in and cut-out pressures, and the charge time from engine
start to cut-out by using KOMTRAX Plus.
(3) According to the results obtained from the above, take corrective actions such as adjusting or
replacing the accumulator charge valve or replacing the pump.
(Reference)
For reference, brake charge pump outlet side oil pressures for (1) normally operating system and
(2) malfunctioning system are shown in 20-***. The values show the pressure when the brake pedal
is repeatedly depressed once in approximately every 10 seconds after the brake oil pressure is
charged.
Refer to page A: 40-519 D: 40-698

B: 40-521, 522 E: 40-679
C: 40-697
40-678 WA1200-6
3) Warning display on multi monitor 40-679

1] Front brake oil pressure too low (during oper- 3] Brake oil level too low (during operation)
ation) This warning display warns about abnormality in the
This warning display warns about abnormality in the brake oil level during operation.
front brake oil pressure. When the brake oil level warning is not displayed on
q If the brake oil pressure lowers 14.72 MPa the multi monitor, the system is normal.
{150 kg/cm2} or less during operation: If the oil level in brake circuits or brake cooler cir-
The title and message appears on the multi cuits is too low, the title and message appears on
monitor as a display of abnormality. In this case, the multi monitor as a display of abnormality. In this
the title screen turns red, the centralized warning case, the title screen turns red, the centralized warn-
lamp (CAUTION) on the main monitor blinks, ing lamp (CAUTION) on the main monitor blinks,
and the alarm buzzer sounds. and the alarm buzzer sounds. If this happens, move
If these alarms are given, stop the work immedi- the machine immediately to a safe place, stop the
ately and check the brake oil pressure system. engine, check the brake oil level, and add oil.
At this time, also check for oil leaks from the brake
system.
2] Rear brake oil pressure too low (during oper-

ation)
This warning display warns about abnormality in the
rear brake oil pressure.
4] Front and rear brake oil pressure too low (at q If the brake oil pressure is 14.72 MPa
engine start) {150 kg/cm2} or less and in process of accumu-
This warning display warns about abnormality in the lating, the title and message appears on the
front brake oil pressure and rear brake oil pressure. multi monitor as a display of abnormality. In this
Front and rear brake accumulated oil pressure dis- case, the title screen turns red, and the central-
play ized warning lamp (CAUTION) on the main mon-
itor blinks.
If these alarms are given, stop the machine and
wait for a while until the brake oil pressure is
accumulated. When pressure is accumulated
(exceeds 14.72 MPa {150 kg/cm2}), the abnor-
mality display on the screen goes out.
WA1200-6 40-679
5] Brake oil level too low (before engine start)

This warning display warns about low oil level.
If the oil level in brake circuits or brake cooler cir-
cuits is too low at the time of check before starting
(starting switch ON and engine not running), the title
and message appears on the multi monitor as a dis-
play of abnormality.
In this case, the title screen turns yellow, and the
centralized check lamp (CHECK) on the main mon-
itor blinks.
If the lamp blinks and the message appears on the
multi monitor, check the brake oil level and add oil.
At this time, also check for oil leaks from the brake
system.
40-680 WA1200-6
3. Checking for internal leaks in components such as valves, accumulators (oil leaks, etc.) 40-681
q Perform troubleshooting by using KOMTRAX Plus or Bouldon tube (locations marked with r and *).
q When checking for leaks in the circuit, block the circuit by installing plugs to locations marked with O on
the emergency parking brake valve and right and left brake valves. (To eliminate effects of these compo-
nents)
WA1200-6 40-681
40-682 WA1200-6

B: 40-657
WA1200-6 40-683

Contents of work
(1) Before checking oil pressures, replace three check valves to eliminate possible defect factors.
(2) In addition, block the circuit by installing plugs to locations marked with O on the emergency
parking brake valve and right and left brake valves. (To eliminate effects of these components)
(3) Measure the accumulator charge cut-in and cut-out pressures, and the charge time from engine
start to cut-out by using KOMTRAX Plus. o Judgment of accumulator
(4) Open the plug on the emergency parking brake valve and depress the brake pedal 5 times.
Check the change in the brake pressure. o Judgment of emergency parking brake valve
(5) Check for leakage from brake valve. o Judgment of brake valve
Causes of leakage
a Since these components cannot be checked individually for leaks, judge by monitoring the
change in circuit oil pressure.
(1) Left brake valve
(2) Right brake valve
(3) Emergency parking brake valve
Causes of pressure not maintained
(1) Gas escaping from accumulator
(2) Damaged accumulator
a See next page for the troubleshooting flow.
40-684 WA1200-6
Refer to page A: 40-685, 686 F: 40-689

B: 40-686 G: 40-693-698
C: 40-686 H: 40-693
D: 40-693-698 I: 40-693-698
E: 40-694 J: 40-693
WA1200-6 40-685
3) Brake related components layout drawing 40-686
40-686 WA1200-6
WA1200-6 40-687
4) Checking of accumulator nitrogen gas pres- Precautions when connecting the gas charge
sure and procedure for charging accumulator tool R1 40-68
with nitrogen gas 40-68 1. Sealant has been applied to the threaded portion
a Testing tools of the adapter (5) for the gas charge tool R1.
Sym- Applicable Never attempt to remove it unless absolutely
Part No. Part name necessary. Otherwise, the gas may leak out.
bol standard
Gas charge tool 2. On some gas valves (4), the length of the
792-610-1701
kit
For old type threads (B) may be not long enough for the
q Gas charge depth (A) from the end face of the adapter (5) to
792-610-1700 ACC
tool the packing (6) of the gas charge tool R1,
07000-11009 q O-ring
preventing the gas valve (4) from seating
1 Gas charge tool
792-610-1702
kit
completely. In such a case, nitrogen gas may
q Gas charge For old and leak out through the threads of the gas valve (4).
792-610-1700 3. When connecting the gas charge tool R1 to the
tool new type ACC
07000-11009 q O-ring gas valve (4) but the extension (P/N:
792-610-2310 q Extension 792-610-2310) supplied with the tool is not avail-
R Nipple able, install O-ring (7) (P/N: 07000-11009)
792-610-1310 GOST
(For Russia) supplied with the tool to gas valve (4). Connect
Nipple
792-610-1320 CGA No.351 the gas charge tool R1. Then, check to ensure
(For USA)
Nipple ASA
that there is no leakage.
792-610-1330
(For USA) B-571-1965
2
DIN 477-1963
Nipple NEN3268-1966
792-610-1350
(For Germany) SIS-SMS
2235/2238
Nipple BS 341
792-610-1360
(For UK) Part1-1962
k Put on proper protection gear (goggles,
leather gloves and protective clothes) so that
the leaking nitrogen gas will not touch your
skin or clothes and work on the windward
side as long as possible.
k When handling nitrogen gas in a room or an- 4. If extension (8) (P/N: 792-610-2310) supplied
other place which is not ventilated well, ven- with the tool is available, install extension (8) to
tilate the work place forcibly and observe the gas valve (4) and then connect gas charge tool
Oxygen Deficiency Prevention Rules of the R1.
Labor Safety and Sanitation Law. a The O-ring supplied with the tool will not be
k The accumulator is charged with high-pres- used.
sure nitrogen gas, so mistaken operation
may cause an explosion, which will lead to
serious injury or damage. When handling the
accumulator, strictly observe the following.
q Do not bring fire near the accumulator or put
the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
q Before disassembly or removal, relieve the
accumulator charge down to the atmospher-
ic pressure.
q Only use nitrogen gas to fill the accumulator.
Do not use oxygen or other explosive gas.
q When handling the accumulator, strictly ob-
serve the precautions given in this manual.
40-688 WA1200-6
Testing nitrogen gas pressure in accumulator 40-689 3) Install extension (8) (P/N: 792-610-2310)
a The measuring is also possible on the accumu- supplied with the tool to gas valve (4) by
lator alone. referring to "Precautions when connecting
a Nitrogen gas cylinder (c) must be connected the gas charge tool R1". Alternatively, install
even when you measure only the gas pressure. the O-ring (7) (P/N: 07000-11009) supplied
1. Stop the engine and depress the brake pedal with the tool to the gas valve (4).
repeatedly to lower the oil pressure in the brake a The O-ring is not used when installing the
circuit to zero. extension.
4) Connect the charge tool R1 to gas valve (4)

on accumulator (1).

4. Connect the gas charge tool R1 to the gas valve

(4) on the accumulator (1) following the steps
below.
1) Turn the handle (a) on the gas charge tool R1
fully counterclockwise.
2) Close the valve of nitrogen gas cylinder (c)
and handle (b).
WA1200-6 40-689
5. Slowly turn clockwise handle (a) of gas charge Procedure for charging accumulator with nitro-
tool R1 and read the gauge. gen gas 40-690
a Since the indicated value varies with the am- a The accumulator can also be charged in a simi-
bient temperature, refer to the following table lar manner when it is separate from the machine.
and check gas pressure. 1. Stop the engine and depress the brake pedal
(The unit of each value in the formula is °C.) repeatedly to lower the oil pressure in the brake
Indicated gas pressure = Standard gas circuit to zero.
pressure x ((273 + t)/(273 + 20)) a Generally, if the brake pedal is depressed 30
Quick reference table for gas pressure in the times, the reaction force to the brake pedal is
accumulator lost and the oil pressure is lowered to zero.
Ambient Gas pressure 2. Remove valve guard (2) and cap (3) from accu-
tempera- Remarks mulator (1). (Old type accumulator)
MPa kg/cm2
ture °C
15 4.34 44.2
16 4.35 44.4
17 4.37 44.5
18 4.38 44.7
19 4.40 44.8
20 4.41 45.0 Standard gas
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8 (New type accumulator)
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.70 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
t: Gas temperature when charging ( °C)
Reference: t may be assumed to be ambient
temperature.
6. If the gas pressure is too high or too low, adjust

it referring to "Procedure for charging accumu-
lator with nitrogen gas".
a Each time the pressure is measured, some
nitrogen gas is discharged and the pressure
lowers. Add nitrogen gas by the loss.
7. Turn handle (a) on gas charge tool R1 fully coun-
terclockwise.
8. Remove gas charge tool R1 from accumulator
(1) and restore them to their original states.
Refer to "Procedure for charging accumulator
with nitrogen gas".
40-690 WA1200-6
4. Following the steps below, connect gas charge

tool R1 and a nitrogen gas cylinder (c) to gas
valve (4) on accumulator (1).
1) Turn handle (a) on gas charge tool R1 fully
counterclockwise.
2) Turn handle (b) to the left to open.
3) Install extension (8) (P/N: 792-610-2310)
supplied with the tool to gas valve (4) by
referring to "Precautions when connecting
the gas charge tool R1". Alternatively, install
the O-ring (7) (P/N: 07000-11009) supplied
with the tool to the gas valve (4).
a The O-ring is not used when installing the
extension.
4) Connect the charge tool R1 to gas valve (4) 5. Slightly open the valve on the nitrogen gas
on accumulator (1). cylinder (c) to discharge nitrogen gas at a pres-
5) Connect gas charge tool R1 to nitrogen gas sure of approx. 0.19 to 0.29 MPa {2 to 3 kg/cm2}.
cylinder (c). 6. After nitrogen gas starts flowing out of handle
a Avoid applying bending load to the gas (b), turn handle (b) to the clockwise to close.
valve (4), which may otherwise break. 7. Turn handle (a) slowly clockwise to open valve
a There are two types of threads of nitrogen (4) of accumulator (1) gradually.
gas cylinders; W22-14 threads (mail a If handle (a) is turned too much, the valve
screw, type A) and W23-14 threads (fe- core of the accumulator will be damaged and
male screw, type B). When using a gas gas will leak. Accordingly, operate handle (a)
cylinder of W23-14 threads (female carefully.
screw, type B), connect the hose by using 8. Open the valve of nitrogen gas cylinder (c)
the adapter. further to charge the accumulator with nitrogen
(The adapter is supplied with the gas gas.
charge tool R1.) 9. During the work, close the valve of nitrogen gas
[Japan domestic] cylinder (c) and check the nitrogen gas pressure
a Use nipple R2 to connect the hose de- in the accumulator.
pending on the specification of the nitro- a Since the indicated value varies with the am-
gen gas cylinder. [Overseas] bient temperature, refer to the following table
to charge gas pressure in the cylinder.
(The unit of each value in the formula is °C.)
Indicated gas pressure = Standard gas
pressure x ((273 + t)/(273 + 20))
WA1200-6 40-691
Quick reference table for gas pressure in the 11. Remove gas charge tool R1 from gas valve (4)
accumulator of accumulator (1) according to the following
Ambient Gas pressure procedure.
tempera- Remarks 1) Turn handle (a) counterclockwise to close
MPa kg/cm2
ture °C the valve of the accumulator.
15 4.34 44.2 2) Turn handle (b) counterclockwise to open
16 4.35 44.4 and discharge nitrogen gas remaining in gas
17 4.37 44.5
18 4.38 44.7
charge tool R1 and hoses.
19 4.40 44.8 3) Remove gas charge tool R1 from gas valve
20 4.41 45.0 Standard gas (4) on the accumulator.
21 4.43 45.2 4) Remove extension (8) from gas valve (4).
22 4.44 45.3 Alternatively, remove O-ring (7) from gas
23 4.46 45.5 valve (4).
24 4.47 45.6 12. Apply soap water to gas valve (4) of the accumu-
25 4.49 45.8 lator to ensure that nitrogen gas is not leaking.
26 4.50 45.9
13. Install plug (9) to accumulator (1).
3 Plug:
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4 73.5 to 98.0 Nm {7.5 to 10.0 kgm}
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.70 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
t: Gas temperature when charging ( °C) 14. Within a week after charging the accumulator
Reference: t may be assumed to be ambient with nitrogen gas, check the operation of the
temperature. brakes following the steps below to ensure that
the nitrogen gas charge has not dropped.
10. After the accumulator is charged to the standard a Check the function within 5 minutes of stop-
pressure, close the valve of nitrogen gas ping the engine. (If more than 5 minutes pass
cylinder (c). after the engine is stopped, oil pressure in the
a If the accumulator is charged too much, turn brake circuit drops too much to effect an ac-
handle (b) counterclockwise slowly with the curate check.)
valve of nitrogen gas cylinder (c) closed to re- 1) Stop the machine on a level ground and set
lease the nitrogen gas gradually to adjust. the parking brake switch in the "PARK" posi-
tion.
2) Start the engine and run it at medium speed
for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and depress the brake pedal repeatedly.
Count the number of depresses until the
brake oil pressure caution lamp lights up.
q Less than 5 depresses: Accumulator gas
charge may have dropped too much.
q 5 depresses or more: Accumulator gas
charge is at a correct level.
40-692 WA1200-6
5) Explanation of brake pump outlet pressure 40-693

[Normal operating condition]
WA1200 system performance at pump delivery 40 cc/rev, part 1
<Oil pressure behavior at pump outlet>
a Oil pressure data of actual machines are shown below for reference.
q Shown here is the behavior of oil pressure at the pump outlet when the brake pedal is repeatedly
depressed once in every 10 seconds, after the brake circuit pressure reaches 210 kg/cm2 and the
engine running at low idle.
q For the pump outlet pressure, see outlet pressure testing gauge on pump in the circuit diagram.
WA1200-6 40-693
40-694 WA1200-6
Many of the problems of the brakes are caused by leaks, however, it is difficult to pinpoint the leakage
by testing the entire system since there are too many parts that may cause leakage.
Therefore, it will be effective to proceed with troubleshooting by replacing low-cost parts and com-
paring the pressure to the standard value.
WA1200 system performance at pump delivery
40 cc/rev, part 2
<Oil pressure behavior at pump outlet>
2
q Shown here is the 210 kg/cm behavior of oil pressure at the pump outlet when the brake pedal is
repeatedly depressed once in every 10 seconds, after the brake circuit pressure reached and the
engine is stopped.
q For the pump outlet pressure, see outlet pressure testing gauge on pump in the circuit diagram.
WA1200-6 40-695
40-696 WA1200-6
6) Measuring accumulator charge cut-in and 4. Measure the accumulator charge cut-out pres-
cut-out pressures 40-697 sure. Measure the oil pressure when the rising
k Be sure to follow "Safety precautions to fol- oil pressure alters to drop. Cut-out pressure:
low before starting work". 20.6 to 22.1 MPa {210 to 225 kg/cm2}
5. Measure the accumulator charge cut-in pres-
Measurement 40-697 sure. Start the engine and run at low idle. While
q Brake oil temperature: 45 to 55 °C observing the pressure drop, measure the
k Stop the engine, then depress the brake ped- minimum pressure when the oil pressure gradu-
al at least 100 times to release the pressure ally alters from drop to rise (read the F brake
inside the accumulator circuit. pressure or R brake pressure on the multi
1. Select "SERVICE MENU SELECT" on the multi monitor).
monitor screen. Cut-in pressure: 17.6 to 18.2 MPa {180 to
2. Use item selection switches [F3] and [F4] to
186 kg/cm2}
select Pm Clinic, and then press [F6] switch to
value is released.
3. Display item "F brake oil pressure" or "R brake

oil pressure" (page 4/4 of Pm Clinic menu
screen).
WA1200-6 40-697
(Reference) Change in accumulator charge pressure
Adjusting 40-698
Accumulator charge cut-in pressure and cut-out
pressure
a When the accumulator charge cut-out pressure
is adjusted, the cut-in pressure also changes in
proportion to the valve area ratio. Therefore, a
cut-in pressure adjustment screw is not provid-
ed.
1. Loosen lock nut (5) of cut-out valve (4), then turn
adjustment screw (6) to adjust the pressure.
creased.
q Turned counterclockwise, the pressure is
decreased.
a Quantity of pressure adjustment per turn of
adjustment screw:
5.59 MPa {57 kg/cm2}
3 Locknut:
9.8 to 11.8 Nm {1 to 1.2 kgm}
a After completion of adjustment, repeat the
measurement procedure given above to
check the accumulator charge cut-in and
cut-out pressures again.
40-698 WA1200-6
7) Checking for brake accumulator oil pressure 4. Disconnect hose (3) between tube (2) of emer-
leakage 40-69 gency parking brake valve (1) and the accumu-
k Be sure to follow "Safety precautions to fol- lator.
frame lock bars.
Testing 40-69
q Start and run the engine until the charge pres-
Charge pressure
2
2
a Check the charge pressure at "F brake oil pres-
sure" or "R brake oil pressure" (page 4/4 of Pm
Clinic menu screen) of the multi monitor.
1. Stop the engine.

2. Turn the starting switch to "ON" position (do not
start the engine) and set the multi monitor screen
to"F brake oil pressure" or "R brake oil pressure"
(page 4/4 of "PM-CLINIC MENU" screen).
k Thoroughly release the remaining pres-
sure.
WA1200-6 40-699
5. Securely install sleeve plug (4) and O-ring (5) to

disconnected tube (2), and install O-ring cap
hose (3).
q Part number of plug installed to tube side:
07376-70422 plug (4)
02896-11012 O-ring (5)
q Part number of plug installed to hose side:
02789-10422 cap (6)
6. Start and run the engine until the charge pres-
2
2
7. When the test is completed, lower the brake oil
pressure to 0 MPa {0 kg/cm2} by referring to
steps 1 to 3.
k Thoroughly release the remaining pres-
sure.
8. Reconnect hose (3) to tube (2).
9. If the pressure dropped below 14.7 MPa
{150 kg/cm2}, check for leaks from the emer-
gency parking brake valve.
40-700 WA1200-6
Information contained in troubleshooting table (H mode)
Information contained in troubleshooting table (H mode) 40-701

(Rev. 2010/03)
a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to the detected failure or troubleshooting
2
Probable causes of failure
(The attached numbers are for <Information described>
filing and reference purpose q Standard value in normal condition to judge probable causes
only. It does not indicate the pri- q Remarks on judgment
ority.)
3
WA1200-6 40-701
H-1 Torque converter oil temperature rises too high (overheats)
H-1 Torque converter oil temperature rises too high (overheats) 40-702
Failure Torque converter oil temperature rises too high (overheats)
Ask the operator and check the following points
(1) Does the torque converter overheat suddenly?
Is any unusual noise heard at the time? And from where? (Breakage of related equipment)
Related infor-
mation (2) In what working condition does it occur? Travelling downhill or during digging?
(3) Is the tire inflation pressure correct?
a Check before troubleshooting: Check if the level and type of oil in the transmission is appropriate
while running the engine at low idle (too much oil results in overheating).

a Engine speed can be checked with monitoring function.
a E: Economy mode
P: Power mode
Engine speed Engine speed (rpm)
Low idle 575 – 725
High idle 1,800 – 2,000
E 1,650 – 2,000
Torque converter stall
1 Defective engine body P 1,700 – 2,000
Hydraulic stall E 1,650 – 2,000

(Lift arm RAISE relief) P 1,700 – 2,000

(Bucket TILT relief) P 1,700 – 2,000
Full stall (torque converter stall + E 1,500 – 2,000

hydraulic stall) P 1,550 – 2,000
a Transmission main relief pressure can be checked with monitoring function.
Oil pressure (MPa
Check item
{kg/cm2})
q Engine coolant temperature: With-Transmis-
Defective transmission main relief in operating range sion main 2.7 ± 0.15
2 relief pres- {28 ± 1.5}
valve q Torque converter oil temperature:
60 – 80 °C sure
Torque con-
q Engine speed: High idle
verter Max. 1.22
inlet oil {max. 13}
pressure
a Torque converter outlet oil pressure can be checked with monitoring func-
tion.
Oil pressure (MPa
q Engine coolant temperature: With- Check item
3
Defective torque converter regula-
in operating range {kg/cm2})
tor valve Torque con-
verter 0.88 ± 0.1
60 – 80 °C
outlet oil {9 ± 1}
pressure
40-702 WA1200-6

a Check the rising transition of torque converter oil temperature from the
KOMTRAX Plus trend data.
q Refer to the transition chart of "T/C oil temp & Engine speed".
q Refer to the transition chart of "T/C oil temp & Vehicle speed".
a If a failure code is displayed on the monitor, perform troubleshooting for it
by referring to the corresponding troubleshooting sheet.
q Failure code: B@CENS (1) Digging time (at torque converter
(Displayed when torque converter stall): Max. 10 sec.
oil temperatures exceeds 130 °C) (2) Travel speed and engine speed
when traveling downhill
4 Defective operation
q Failure code: b@CENS q Forward 1st: Max. 7 km/h and en-
(Displayed when torque converter gine speed 1,650 rpm or higher
oil temperatures exceeds 120 °C) q Forward 2nd: Max. 12 km/h and
engine speed 1,650 rpm or higher
(1) Travel speed and engine speed
when traveling downhill
q Failure code: 1540N1
q Forward 1st: Max. 7 km/h and en-
(Overrun displayed when 3rd
gine speed 1,650 rpm or higher
speed cut-off option selected)
q Forward 2nd: Max. 12 km/h and
engine speed 1,650 rpm or higher
a Check torque converter oil cooler performance
q Engine at high idle Standard value
Check item
q Torque converter stall (MPa {kg/cm2})
Measure torque converter inlet and Inlet pressure 0.3 – 0.5 {3 – 5}
Defective torque converter oil outlet pressures under above condi- Outlet pres-
5 0.15 – 0.25 {1.5 – 2.5}
cooler tions sure
Check item Standard value ( °C)
Measure torque converter inlet and
outlet temperatures under above con- Difference
ditions between oil 11 to 13
temperatures
a Measure fan speed for additional cooler
q Engine speed: High idle Fan speed (rpm)
STD: 2,050 ± 50 rpm
100 rpm lowered specification:
1,900 ± 50 rpm 2,000 ± 100
6 Defective additional oil cooler 55 °C
a Measure priority relief valve set pressure
q Hydraulic oil temperature: 45 to Set pressure ( MPa {kg/cm2})
55 °C 14.7 ± 1.0 {150 ± 10}
a Check the oil cooler for clogging and clean if clogged.
WA1200-6 40-703

a Transmission modulation oil pressure can be checked with monitoring func-
tion.
q Engine coolant temperature: With- Modulation clutch oil pressure
in operating range (MPa {kg/cm2})
60 to 80 °C
q Turn the drive force and the travel 2.45 ± 0.15
speed control dials fully clockwise. {25 ± 1.5}
7 Defective modulation clutch q Set directional lever in NEUTRAL
and run engine at high idle
a Check the transition of modulation clutch oil pressure from the KOMTRAX
Plus trend data.
q If a failure code [DBD0KT], [DXHPKZ], or [DW23KZ] is displayed, perform
troubleshooting for it by referring to the corresponding troubleshooting
sheet.
a Check if metallic powder is adhered to the strainer or inside of filter for the
transmission and clean as necessary.
a Check if metallic powder is adhered to the strainer or inside of filter for the
Defective transmission or torque
8 transmission. If metallic powder is found, judge that the charging pump is
converter charging pump
defective.
a If no failure is found by checks on causes 1 to 8 above, there may be an
9 Internal defect of torque converter
internal defect in the torque converter. Check it directly.
40-704 WA1200-6
H-2 Turning or response of steering is poor
H-2 Turning or response of steering is poor 40-705

Failure Turning or response of steering is poor.
(1) Does the turning of machine become poor suddenly?
Related infor-
mation (2) Were there any symptoms of dull steering response previously?
a Check before troubleshooting: Check whether the level and type of oil in the hydraulic tank is ap-
propriate.

a E: Economy mode
P: Power mode
Low idle 575 – 725
High idle 1,800 – 2,000
1 Defective engine body E 1,650 – 2,000
P 1,700 – 2,000


a Steering oil pressure can be checked with monitoring function.
q Lock the front and rear frames by using frame lock bars, and chock the
wheels.
q Hydraulic oil temperature: 45 to Oil pressure (MPa

Check item
55 °C {kg/cm2})
Defective surge cut oil
q Engine speed: Low idle
pressure valve
q Screw-in the main relief valve by a R.H. steering 33.3 – 34.3
half turn valve oil pressure {340 – 350}
q Measure the steering serge-cut oil
Defective pressure when the joystick lever is L.H. steering 33.3 – 34.3
2 steering moved to the right or left to relief. valve oil pressure {340 – 350}
valve
Oil pressure (MPa
Check item
q Hydraulic oil temperature: 45 to {kg/cm2})
55 °C
Defective main relief q Engine speed: High idle R.H. steering 31.36(+0.98/-1.27)
valve q Measure the steering oil pressure valve oil pressure {320(+10/-13)}
when the joystick lever is moved to
the right or left to relief. L.H. steering 31.36(+0.98/-1.27)
valve oil pressure {320(+10/-13)}
a If steering relief pressure is unstable at only one side, or jolts at only one
side during work or travel with steering in NEUTRAL position
Defective suction safety valve of q If oil pressure in step 2 is lower than the standard value and the set pressure
3
steering valve does not rise even when the relief valve is adjusted, interchange the safety
valves for the right and left swing circuits and check if the phenomenon
changes.
WA1200-6 40-705

a If the steering jolts to the right or left at near the NEUTRAL position when
Defective demand valve of steer-
4 the work equipment is operated, the demand valve may be defective. Check
ing valve
the movement of the spool directly.
q Lock the front and rear frames by Oil pressure (MPa
Check item
using frame lock bars, and chock {kg/cm2})
the wheels. AJSS lever in 0.47 – 0.62
q Engine at low idle NEUTRAL {4.8 – 6.3}
5 Defective steering EPC valve
q Slowly move the steering control 0.88 – 1.08
Right turn
lever right and left at near the NEU- {9 – 11}
TRAL position and then read the 0.88 – 1.08
Left turn
pressure when it is at the minimum. {9 – 11}
a Measuring play of steering control lever
q Engine at low idle Standard value
q Set the machine in the straight trav- for new machine Repair limit (mm)
el position, and slowly move the (mm)
Defective steering control lever steering control lever to the right
6 (left). At certain point, machine
(AJSS)
starts to turn. Then move the steer-
ing control lever to the left (right). At Max. 8 Max. 10
certain point, machine starts to turn
to the other direction. Measure the
stroke between those two points.
a Check the steering follow-up linkage
Check item Standard value
Length of the fol-
low-up linkage 342 mm
rod
Defective steering follow-up link- q Engine stopped Lever angle
7
age q Set the machine in the straight trav- potentiometer 2.5 ± 0.3 V
el position. voltage at NEU-
TRAL
Frame angle
potentiometer
2.5 ± 0.3 V
voltage at NEU-
TRAL
a Measure the clearance between front frame end stopper and rear frame
q Engine at low idle Check item Standard value
Defective adjustment of steering q Steer to the right and left, and mea-
8 Clearance
stopper bolt sure the clearance between front between the front
and rear frames when the steering frame and rear 37 – 40 mm
stops. frame
a Check the rotary valve (Orbit-roll)
Standard value (Nm
Check item
{kgm})
q Engine stopped
Defective rotary valve q Measure the input torque when the Valve displace-
9 1.47 – 1.96
(Orbit-roll) output shaft is locked ment
{0.15 – 0.20}
angle10 deg.
q Measure the input torque when the 0.98

–
output shaft is free {0.10}
a If no failure is found by checks on causes 1 to 9 above, the steering cylinder
10 Defective steering cylinder
may be defective. Check it directly.
40-706 WA1200-6

a If the work equipment is operating normally but steering is slow, judge that
the switch pump is normal.
a If unusual noise is heard from around the steering pump or no failure is
found by checks on causes 1 to 10 above, measure the steering time.
11 The steering pump is defective q Hydraulic oil temperature: 45 to Steering time
Engine speed
55 °C (sec.)
q Measure the time required for Low idle Max. 5.7
steering right (left) end to left (right)
end. High idle Max. 4.9
WA1200-6 40-707
H-3 AJSS lever is hard to operate
H-3 AJSS lever is hard to operate 40-708

Failure AJSS lever is hard to operate
(1) Does the AJSS lever become suddenly hard to operate?
Related infor-
mation (2) Were there any symptoms of stiff AJSS lever previously? (Wear of related equipment)
propriate.

Operating effort (N
a Measure the AJSS lever operating Check item
{kg})
effort
q Engine coolant temperature: With- NEUTRAL o Max. 23.5
in operating range Right end {max. 2.4}
q Hydraulic oil temperature: Within
operating range NEUTRAL o Max. 23.5
q Engine speed: Low idle Left end {max. 2.4}
a Measure the play of AJSS lever Check item Play (mm)
Engine at low idle
q
q Set the machine in the straight trav-
1 Defective AJSS Lever
el position, and slowly move the
steering control lever to the right
(left). At certain point, machine
starts turning. Then move the Play of
Max. 10
steering control lever to the left AJSS lever
(right). At certain point, machine
starts turning to the other direction.
Measure the stroke between these
two points.
a If the lever is hard to move even when the joint between steering shaft and
rotary valve is disconnected, check around the linkage.
wheels.
Oil pressure (MPa
Check item
{kg/cm2})
55 °C R.H. steering
Defective surge cut oil 33.3 – 34.3
q Engine speed: Low idle valve oil pres-
pressure {340 – 350}
q Screw-in the main relief valve by a sure
half turn
q Measure the oil pressure when the
Defective joystick lever is moved to the right L.H. steering
2 steering or left to relief. 33.3 – 34.3
valve oil pres-
valve {340 – 350}
sure
Oil pressure (MPa

Check item
{kg/cm2})
55 °C R.H. steering
31.0 – 31.9
q Engine speed: High idle valve oil pres-
Defective relief valve {316 – 325}
q Measure the steering oil pressure sure
L.H. steering
the right or left to relief. 31.0 – 31.9
valve oil pres-
{316 – 325}
sure
40-708 WA1200-6
H-3 AJSS lever is hard to operate

Oil pressure (MPa
Lock the front and rear frames by Check item
q {kg/cm2})
using frame lock bars, and chock
AJSS lever in 0.47 – 0.62
the wheels.
NEUTRAL {4.8 – 6.3}
q Engine at low idle
Right turn
TRAL position and then read the
pressure when it is at the minimum. 0.88 – 1.08
Left turn
{9 – 11}
Standard value (Nm
Check item
q Engine stopped {kgm})
4 1.47 – 1.96
{0.15 – 0.20}
q Measure the input torque when the angle10 deg.
output shaft is free 0.98
–
{0.10}
a If troubleshooting cannot be accomplished by the above items, perform troubleshooting by referring to "H-2
5
Turning or response of steering is poor".
WA1200-6 40-709
H-4 Steering shakes or jolts
H-4 Steering shakes or jolts 40-710

Failure Steering shakes or jolts
(1) Does the steering start to shake or jolt suddenly?
Related infor-
mation (2) Were there any symptoms of steering shake or jolts previously?
propriate.

a E: Economy mode
P: Power mode
Low idle 575 – 725
High idle 1,800 – 2,000
1 Defective engine body E 1,650 – 2,000
P 1,700 – 2,000


wheels.
Oil pressure (MPa
Check item
{kg/cm2})
55 °C
Defective surge cut oil R.H. steering 33.3 – 34.3
q Engine speed: Low idle
pressure valve oil pressure {340 – 350}
q Screw-in the main relief valve by a
half turn
q Measure the oil pressure when the
Defective joystick lever is moved to the right
2 steering or left to relief. L.H. steering 33.3 – 34.3
valve valve oil pressure {340 – 350}
Oil pressure (MPa

Check item
{kg/cm2})
55 °C R.H. steering 31.0 – 31.9
Defective main relief q Engine speed: High idle valve oil pressure {316 – 325}
valve q Measure the steering oil pressure
the right or left to relief. L.H. steering 31.0 – 31.9
valve oil pressure {316 – 325}
a If steering relief pressure is unstable at only one side, or jolts at only one
side during work or travel with steering in NEUTRAL position
Defective suction safety valve of q If oil pressure in step 2 is lower than the standard value and the set pressure
3
steering valve does not rise even when the relief valve is adjusted, interchange the safety
valves for the right and left swing circuits and check if the phenomenon
changes.
40-710 WA1200-6
H-4 Steering shakes or jolts

a If the steering jolts to the right or left at near the NEUTRAL position when
Defective demand valve of steer-
4 the work equipment is operated, the demand valve may be defective. Check
ing valve
the movement of the spool directly.
Oil pressure (MPa
q Lock the front and rear frames by
Check item
{kg/cm2})
using frame lock bars, and chock
AJSS lever in 0.47 – 0.62
the wheels.
NEUTRAL {4.8 – 6.3}
q Engine at low idle
Right turn
TRAL position and then read the
pressure when it is at the minimum. 0.88 – 1.08
Left turn
{9 – 11}
a Measuring play of steering control lever
q Engine at low idle Standard value
q Set the machine in the straight trav- for new machine Repair limit (mm)
el position, and slowly move the (mm)
steering control lever to the right
Defective steering control lever (left). At certain point, machine
6
(AJSS) starts turning. Then move steering
control lever to the left (right). At
Max. 8 Max. 10
certain point, machine starts turn-
ing to the other direction. Measure
the stroke between these two
points.
a Check the steering follow-up linkage
Check item Standard value
Length of the fol-
low-up linkage 342 mm
rod
Defective steering follow-up link- q Engine stopped Lever angle
7
age q Set the machine in the straight trav- potentiometer 2.5 ± 0.3 V
el position. voltage at NEU-
TRAL
Frame angle
potentiometer
2.5 ± 0.3 V
voltage at NEU-
TRAL
a Measure the clearance between front frame end stopper and rear frame
q Engine at low idle Check item Standard value
Defective adjustment of steering q Steer to the right and left, and mea-
8 Clearance
stopper bolt sure the clearance between front between the front
and rear frames when the steering frame and rear 37 – 40 mm
stops. frame
Standard value (Nm
Check item
q Engine stopped {kgm})
9 1.47 – 1.96
{0.15 – 0.20}
angle10 deg.
q Measure the input torque when the 0.98
–
output shaft is free {0.10}
a If no failure is found by checks on causes 1 to 9 above, the steering cylinder
10 Defective steering cylinder
may be defective. Check it directly.
WA1200-6 40-711
H-5 Wheel brake does not work at all or is weak
H-5 Wheel brake does not work at all or is weak 40-712

Failure Wheel brake does not work at all or is weak (failure code is issued)
(1) Does the brake become weak suddenly? (Is the failure code issued at the time?)
(2) Did the brake become weak during work in the past? (Was the failure code issued from time to
time?)
Related informa- (Wear of related equipment) ... Check if failure codes for the KOMTRAX Plus controller are issued
tion
(3) Were there any symptoms of parking brake activation during work previously? (Wear of related
equipment)
Check the KOMTRAX Plus snap shot and failure codes
a Check before troubleshooting: Check whether the level and type of oil in the brake oil tank is ap-
propriate.

Category Oil level
q Empty the brake accumulator and
check the oil level (depress the
Tank for brake
right and left brake pedals alter-
cooling
nately until the pedal operating ef- Between Hi and Low
fort becomes small). on tank gauge
q Check with the engine running at
1 Defective brake oil level Brake oil tank
low idle

q Failure code: B@C5ZK Displayed during work
q Failure code: b@C5ZK Displayed before the engine is started
a Download the KOMTRAX Plus snap shot and check
q Engine at low idle Brake oil pressure
Parking brake: OFF Category
q (MPa {kg/cm2})
q Directional selector switch "N" Caution issue- 14.7
Under the above conditions, depress dioCleared {150}
the right and left brake pedals alter-
nately. Measure the oil pressure when Emergency P
11.3 – 13.3
the oil pressure is decreased and cau- brake
{115 – 135}
2 Defective oil pressure switches tion issued and when the caution is ONioOFF
cleared.
a Check the brake oil pressure on the multi monitor.
(Not only once but two or three times.)
q Failure code: 2G42ZG (During op-
Front brake oil pressure too low
eration)
q Failure code: 2G43ZG (During op-
Rear brake oil pressure too low
eration)
a Check the accumulator charge cut-in and cut-out pressures on the multi
monitor (not only once but two or three times)
(1) Stop the engine, then depress the Oil pressure (MPa
brake pedal at least 100 times to Category
{kg/cm2})
3 Defective charge valve release the pressure inside the 17.6 – 18.2
accumulator circuit. Cut-in
{180 – 186}
(2) Check while running the engine at
20.6 – 22.1
low idle (measurement procedure Cut-out
{210 – 225}
is same as step 2 above)
40-712 WA1200-6
H-5 Wheel brake does not work at all or is weak

a Check the following items to judge whether the charge pump is defective or
not
(1) The oil pressure cannot be adjusted as
described in steps 2 and 3 above (does not
Defective brake charging pump
4 reach the standard value) Clean, replace, or cor-
system
(2) Unusual noise is heard or heat is generated at rect the parts judged as
around the pump defective
(3) Oil filter (strainer) before the charge valve is
clogged
a Check hydraulic leakage from the accumulator
(1) Oil temperature: 45 to 55 °C Holding oil pressure
(2) Run the engine at low idle, and then stop when (MPa {kg/cm2})
the brake oil pressure reaches 20.6 MPa
{210 kg/cm2} Min. 14.7
(3) Keep the engine stopped for 15 minutes, then {min. 150}
measure the holding oil pressure.
a Measure the accumulator gas pressure
(1) Ambient temperature20 °C Gas pressure (MPa
(2) Stop the engine and depress the brake pedal {kg/cm2})
5 Defective brake accumulator repeatedly until the operating effort becomes
4.41
small to lower the oil pressure in the brake circuit
{45.0}
to zero.
a Check whether the accumulator gas pressure drops
*Perform the check within 5 minutes after stopping Number of pedal strokes
the engine.
(1) Start the engine and run it at medium speed for
1 minute and then stop it.
(2) Turn the starting switch to the ON position and 5 times or more
count the number of times needed to depress (normal)
the brake pedal to let the brake caution lamp
light up.
a Measure the leakage from emergency parking brake valve
(1) Start the engine, confirm that the pressure has Oil leakage (cc)
Defective emergency parking reached the accumulator charge valve cut-out
6 pressure on the monitor, and then stop the
brake solenoid valve
engine. Max. 80/minute (brake oil
(2) Disconnect the return hose of solenoid valve and temperature: 45 to 55 °C)
measure the amount of leakage from the hose.
a Measure the leakage from brake valve
(1) Start the engine, confirm that the pressure has Oil leakage (cc)
7 Defective brake valve pressure on the monitor, and then stop the
engine. Max. 64/minute (brake oil
(2) Disconnect the drain hose of brake valve and temperature: 45 to 55 °C)
measure the amount of leakage from the hose.
WA1200-6 40-713
H-6 Lift arm speed is low or lift arm rising force is insufficient
H-6 Lift arm speed is low or lift arm rising force is insufficient 40-714
Failure The lift arm moves slowly or the lift arm rising force is insufficient
(1) Does the work equipment speed suddenly become slower? Is any unusual noise heard at the time?
And from where? (Breakage of related equipment)
Related infor-
mation (2) Does the speed become slower as the oil temperature rises? (Wear of related equipment)
(3) Were there any symptoms of slow work equipment speed previously? (Wear of related equipment)
propriate.

Defective work equipment control
1 a Check for play due to wear or loosening and adjust as necessary.
lever linkage
a E: Economy mode
P: Power mode
Low idle 575 – 725
High idle 1,800 – 2,000
E 1,650 – 2,000



a PPC oil pressure can be checked with monitoring function.
q Engine at high idle 3.72 – 3.92 MPa
q Work equipment relief {38 – 40 kg/cm2}
3 Defective PPC oil pressure
a Measure at lift arm RAISE PPC port of control valve
Work equipment relief {38 – 40 kg/cm2}
a Operation check of work equipment valve for work equipment speed
Lift arm rising time
Engine speed
q Lift arm RAISE operation (sec.)
(ground level to max. height) High idle 20 – 23
q Bucket with no load
Low idle 36 – 39
4 Defective main control valve a Measure the work equipment rising time for each condition of the work
equipment valves.
q According to the condition table for the referred item, block the correspond-
ing PPC port and measure the boom rising time for each condition.
a Measure the main relief set pressure of each valve.
a Main relief pressure can be checked with monitoring function.
q Bucket TILT relief {317 – 330 kg/cm2}
40-714 WA1200-6

a Measure the PV valve relief set pressure
5 Defective PV control valve 2.8 – 3.2 MPa
q Engine at high idle
{28 – 32 kg/cm2}
a Measure at ports P1 and P2 of ES valve for the No. 2 work equipment
pump.
Differential pressure
Defective Engine speed
6 (MPa {kg/cm2})
differential pressure valve q Forward 3rd or reverse 3rd
and brake pedals depressed Low idle 0
High idle 0.5 – 0.6 {5 – 6}
a Measure cut-off solenoid valve outlet pressure.
Pressure at port P1
q Pressure at port P1 when speed Max. 0.3 MPa
exceeds 10 km/h while travelling
Defective work equipment cut-off forward or reverse {max. 3 kg/cm2}
7
solenoid valve (NC valve) q Pressure at port P1 when speed is
Min. 3 MPa
below 10 km/h while travelling for-
ward or reverse {min. 30 kg/cm2}
a If a defect in the electrical system of the solenoid circuit is suspected, per-
form troubleshooting according to "Open circuit, short circuit or hot short
circuit in NEUTRAL cut solenoid".
a Measure ES valve outlet pressure
ES valve outlet pressure
q While running the engine at high
Defective work equipment pump idle, move the bucket control lever
8
ES valve slowly to the TILT direction and
1.8 MPa
measure the ES valve outlet pres-
sure when the differential pressure {18.34 kg/cm2}
in step 6 is 0.33 MPa
{3.35 kg/cm2}.
a Measure the CO cut-off pressure and CO output pressure of each pump
CO valve oil pressure
Pump classification (MPa {kg/cm2})
Cut-off Output
q Measure while running the en- pressure pressure
9 Defective CO valve gine at low idle and moving the 27.5 0.37
bucket control lever slowly to- No. 1 loader pump {280} {3.8}
ward the TILT relief position 25.2 0.74
No. 2 loader pump
{260} {7.6}
29.4 0.37
Switching pump
{300} {3.8}
a Measure NC valve output pressure of each pump.
NC valve oil pressure
Pump classification
q Engine at low idle (MPa {kg/cm2})
10 Defective NC valve q Work equipment lever is in No. 1 loader pump Min. 2.0
neutral (R) {min. 20.0}
q Directional selector switch "N" Min. 2.0
Switch pump (F)
{min. 20.0}
WA1200-6 40-715

a Measure hydraulic drift of work equipment.
q Hydraulic oil temperature: 45 Measuring position Drop amount (mm)
to 55 °C
Bucket hinge pin
q Stop the engine and leave it Max. 250
drop amount
11 Defective work equipment cylinder for five minutes, then take
measurement for 15 minutes. Bucket cutting
q Bucket with no load Max. 100 (Note)
edge drop amount
q With lift arm and bucket level
(Note) Does not include bucket hinge pin drop amount
Judge which hydraulic pump is defective by data obtained from above steps 4,
12 Defective hydraulic pump
9, and 10.
40-716 WA1200-6
H-7 Shock is large when lift arm stops
H-7 Shock is large when lift arm stops 40-717

Failure Shock is large when lift arm stops
(1) Does the shock become large suddenly? o Is any unusual noise heard at the time? o And from
where?
Related infor- (Breakage of related equipment)
mation
(2) Is this happening after the PPC valve or main control valve assembly has been replaced?
propriate.

Defective work equipment control
1 a Check for play due to wear or loosening and adjust as necessary
lever linkage
a Directly check the PPC valve outlet orifice
Valve port Orifice diameter
2 Defective PPC valve outlet orifice
Lift arm RAISE, LOWER f2.0
Bucket TILT, DUMP f10.0
a Directly check the main control valve PPC port orifice
Defective main control valve PPC PPC port Orifice diameter

3
port orifice Lift arm LOWER f2.6
Bucket TILT f2.0
a If the lift arm control lever detent switch is suspected to be defective, per-
Defective lift arm control lever
4 form troubleshooting by referring to the corresponding troubleshooting
detent switch
sheet.
a E: Economy mode
P: Power mode
Low idle 575 – 725
High idle 1,800 – 2,000
E 1,650 – 2,000



WA1200-6 40-717
H-8 Hydraulic oil temperature rises too high (overheating)
H-8 Hydraulic oil temperature rises too high (overheating) 40-718

Failure Hydraulic oil temperature rises too high (overheating)
(1) Does the hydraulic oil overheat suddenly?
Related infor-
mation (2) In what working condition does it occur? During digging?
a Check before troubleshooting: Check whether the level and type of hydraulic oil is appropriate.
Check with the engine stopped.
(Excessive oil will cause overheating)

a E: Economy mode
P: Power mode
Low idle 575 – 725
High idle 1,800 – 2,000
E 1,650 – 2,000



a Check the rising transition of hydraulic oil temperature from the KOMTRAX
Plus trend data.
q Refer to the transition chart of "Hydraulic oil temp".
a Check the transition of hydraulic oil pressure from the KOMTRAX Plus
3 Defective operation trend data.
q See failure code [B@HANS].
a Measure the work equipment rising time for each condition of the work
equipment valves
q According to the condition table for the referred item, block the correspond-
ing PPC port and measure the lift arm rising time for each condition
4 Defective main control valve a Measure the main relief set pressure of each valve
a Main relief set pressure can be checked with monitoring function.
q Engine speed: High idle 31.1 – 32.3 MPa
q Bucket TILT relief {317 – 330 kg/cm2}
40-718 WA1200-6

a Measure the air flow across the hydraulic oil cooler
q Engine speed: 1,900 rpm Average wind speed standard value
5 Insufficient cooling air flow q Measure the wind speed at the rear
of the radiator and hydraulic oil Min. 15 m/s
cooler by using anemometer
a Check the hydraulic oil cooler performance by measuring the temperature
difference between the cooler inlet and outlet
q Engine speed: High idle Difference in temperature between
6 Defective hydraulic oil cooler
q Engine coolant temperature: With- cooler inlet and outlet
in operating range
11 – 13 °C
q Hydraulic oil temperature: 60 °C
a Measure the hydraulic oil cooler cold valve operation pressure
Hydraulic oil cooler
Engine speed
Defective hydraulic oil cooler cold inlet pressure
7 q Hydraulic oil cooler Rated speed 0.45 – 0.6 MPa
relief valve
oil temperature: 40 °C (1,900 rpm) {4.7 – 6.3 kg/cm2}
High idle (2,050 0.45 – 0.6 MPa
rpm) {4.7 – 6.3 kg/cm2}
(Reference) Service News (AT09060) announces the change of the bypass valve set pressure to a higher value to
ensure a sufficient hydraulic oil cooling capacity.
WA1200-6 40-719
40-720 WA1200-6
SEN0547527-00 50-1
WA1200-6
WHEEL LOADER
Shop Manual 5-01
WA1200-6

WA1200-6 60001 and up
50 Disassembly and assembly 50-1
WA1200-6 50-1
Contents
Contents 50-2
50 Disassembly and assembly
General information on disassembly and assembly ............................................................... 50- 4
How to read Disassembly and Assembly............................................................................. 50- 4
Coating materials list............................................................................................................ 50- 6
Special tool list ..................................................................................................................... 50- 9
Sketches of special tools ..................................................................................................... 50- 14
Flushing procedure ................................................................................................................. 50- 54
Flushing procedure for brake circuit..................................................................................... 50- 54
Flushing procedure for work equipment and steering circuit ............................................... 50- 60
Air bleeding procedure............................................................................................................ 50- 66
Bleeding air from brake circuit ............................................................................................. 50- 66
Bleeding air from piston pump ............................................................................................. 50- 68
Bleeding air from work equipment circuit and steering circuit.............................................. 50- 69
Removal and installation of radiator and hydraulic oil cooler assembly............................... 50- 72
Removal and installation of engine assembly...................................................................... 50- 79
Removal and installation of air-cooled torque converter and transmission,
and brake oil cooler assembly .............................................................................. 50- 86
Removal and installation of water-cooled torque converter and transmission
oil cooler assembly ............................................................................................... 50- 88
Removal and installation of damper assembly .................................................................... 50- 89
Disassembly and assembly of damper ................................................................................ 50- 91
Removal and installation of bumper and fuel tank assembly............................................... 50- 98
Removal and installation of hood assembly......................................................................... 50- 100
Disassembly and assembly procedures for MESABI oil cooler ........................................... 50- 102
Disassembly and assembly of MESABI oil cooler ............................................................... 50- 105
Power train.............................................................................................................................. 50- 113
Removal and installation of torque converter and transmission assembly .......................... 50- 113
Disconnection and connection of transmission assembly and torque converter assembly . 50- 120
Disconnection and connection of torque converter assembly, PTO and transfer assembly 50- 127
Disassembly and assembly of torque converter .................................................................. 50- 131
Disassembly and assembly of modulation clutch ................................................................ 50- 142
Disassembly and assembly of PTO and transfer................................................................. 50- 146
Disconnection and connection of transmission assembly, transfer, and parking
brake assembly .................................................................................................... 50- 159
Disassembly and assembly of transmission assembly ........................................................ 50- 166
Disassembly and assembly of transfer ................................................................................ 50- 187
Disassembly and assembly of parking brake....................................................................... 50- 194
Removal and installation of parking brake assembly (installed on the machine)................. 50- 197
Removal and installation of transmission, brake cooling device and brake pump assembly 50- 201
Removal and installation of steering pump, control pump and PPC pump assembly.......... 50- 202
Disassembly and assembly of drive shaft............................................................................ 50- 203
Removal and installation of front axle assembly.................................................................. 50- 205
Removal and installation of front final drive assembly ......................................................... 50- 207
Removal and installation of rear axle assembly................................................................... 50- 209
Removal and installation of rear final drive assembly.......................................................... 50- 220
Removal and installation of differential assembly ................................................................ 50- 223
Disassembly and assembly of differential............................................................................ 50- 225
Disassembly and assembly of final drive and brake ............................................................ 50- 238
Removal and installation of center support assembly.......................................................... 50- 251
Disassembly and assembly of center support ..................................................................... 50- 253
50-2 WA1200-6
Contents
Steering system ...................................................................................................................... 50- 257

Removal and installation of steering demand valve assembly ............................................ 50- 257
Removal and installation of steering cylinder assembly ...................................................... 50- 258
Removal and installation of emergency diverter valve assembly ........................................ 50- 262
Removal and installation of emergency steering pump assembly ....................................... 50- 264
Brake system .......................................................................................................................... 50- 265
Removal and installation of brake accumulator charge valve assembly ............................. 50- 265
Removal and installation of brake oil tank assembly ........................................................... 50- 266
Procedure for disconnecting front frame and rear frame ..................................................... 50- 267
Removal and installation of center hinge pin ....................................................................... 50- 268
Removal and installation of hydraulic tank, filter case assembly......................................... 50- 284
Removal and installation of No. 1 work equipment pump assembly ................................... 50- 286
Removal and installation of No. 2 work equipment pump assembly ................................... 50- 288
Removal and installation of switch pump assembly ............................................................ 50- 289
Removal and installation of work equipment control valve assembly .................................. 50- 290
Work equipment...................................................................................................................... 50- 304
Removal and installation of bucket cylinder assembly ........................................................ 50- 304
Removal and installation of lift cylinder assembly ............................................................... 50- 315
Disassembly and assembly of work equipment cylinder ..................................................... 50- 329
Removal and installation of work equipment assembly ....................................................... 50- 335
Procedure for running in bucket pin..................................................................................... 50- 391
Procedure for running in lift arm pin..................................................................................... 50- 393
Cab ......................................................................................................................................... 50- 396
Removal and installation of bulkhead assembly .................................................................. 50- 396
Removal and installation of operator's cab and floor assembly........................................... 50- 398
Removal and installation of operator's cab assembly.......................................................... 50- 402
Removal and installation of air conditioner unit assembly ................................................... 50- 404
Disassembly and assembly of operator seat ....................................................................... 50- 406
Removal and installation of DT connector pin ..................................................................... 50- 439
Removal and installation of HD connector pin..................................................................... 50- 441
Repairing HD connector pin harness................................................................................... 50- 442
Removal and installation of controller assembly.................................................................. 50- 443
WA1200-6 50-3
General information on disassembly and assembly
How to read Disassembly and Assembly
General information on disassembly and assembly 50-4

How to read Disassembly and Assembly 50-4
(Rev. 2009. 01)
1. Removal and installation of assemblies 50-4
Special tools 50-4 [*1] : This mark shows that instructions or

q Special tools which are necessary for removal or precautions for parts installation work are
installation of parts are described as A1 ..... X1, given in "Installation" section.
etc. and their part numbers, part names and 6 : Amount of oil or coolant to be
quantities are described in the special tool list. drained.
q In the special tools table, the following informa- 4 : Weight of part or component
tion is described, as well as the above items.
1) Necessity Installation 50-4
t: Special tools that cannot be substituted q Unless otherwise instructed, installation of parts
and should always be used. is to be done in the reverse order to removal.
q: Special tools that will be useful if available q Instructions and precautions for parts installation
and are substitutable with tools available are shown with the mark (e.g.[*1]) which corre-
on the market. sponds to the mark in "Removal" section.
2) New/redesign q Common tools that are necessary for installation
N : Tools newly developed for this model. are described as [1], [2]••• etc. and their part
They have a new part number respec- numbers, part names and quantities are not de-
tively. scribed.
R : Tools made available by redesigning q Marks shown in the "Installation" section stand
the existing tools which were devel- for the following.
oped for other models. Each of them k : Precautions related to work safety
has a new part number assigned by a : Know-how or precautions for work
setting forward the part number of the 2 : Type of coating material
existing tool. 3 : Tightening torque
Blank :Tools already available for other 5 : This mark indicates the amount of oil
models. They can be used without any or coolant to be added.
modification.
3) Circle mark (Q) in sketch column. Sketches of special tools 50-4
q The sketch of the special tool is present- q Various special tools are illustrated for the local
ed in the section of “Sketches of special manufacture.
tools”.
q Part No. of special tools starting with
79*T-***-**** means that they are not
available from Komatsu Ltd. (tools to be
made locally).
Removal 50-4
q In "Removal" section, the work procedures, pre-
cautions and know-how to do the work, and the
amount of oil and coolant to be drained are de-
scribed.
q Common tools that are necessary for removal
are described as [1], [2]••• etc. and their part
numbers, part names and quantities are not de-
scribed.
q Various symbols used in "Removal" section are
explained and listed below.
k :This mark indicates safety-related precau-
tions which must be followed when doing the
work.
a : Know-how or precautions for work
50-4 WA1200-6
How to read Disassembly and Assembly
2. Disassembly and assembly of assembly 50-5

Special tools 50-5 Assembly 50-5
q Special tools which are deemed necessary for q In "Assembly" section, the work procedures, pre-
disassembly or assembly of parts are described cautions and know-how to do the work, and the
as A1? ..... X1, etc. and their part names, part amount of oil and coolant to be replenished are
numbers and quantities are described in the described.
special tool list. q General tools that are necessary for assembly
q In the special tools list, the follwing information is are described as [1], [2]••• etc. and their part
described, as well as the above items. numbers, part names and quantities are not de-
1) Necessity scribed.
t: Special tools that cannot be substituted q The meanings of the symbols used in "Assem-
and should always be used. bly" section are as follows.
q: Special tools that will be useful if available k :This mark indicates safety-related precau-
and are substitutable with tools available tions which must be followed when doing the
on the market. work.
2) New/redesign a : Know-how or precautions for work
N : Tools newly developed for this model. 2 : Type of coating material
They have a new part number respec- 3 : Tightening torque
tively. 5 : This mark indicates the amount of oil
R : Tools made available by redesigning or coolant to be added.
the existing tools which were devel-
oped for other models. Each of them Sketches of special tools 50-5
has a new part number assigned by q Various special tools are illustrated for the local
setting forward the part number of the manufacture.
existing tool.
Blank :Tools already available for other
models. They can be used without any
modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is present-
ed in the section of “Sketches of special
tools”.
q Part No. of special tools starting with
79*T-***-**** means that they are not
available from Komatsu Ltd. (tools to be
made locally).
Disassembly 50-5
q In "Disassembly" section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q General tools that are necessary for disassem-
bly are described as [1], [2]•••etc. and their part
names, part numbers and quantities are not de-
scribed.
q The meanings of the symbols used in "Disas-
sembly" section are as follows.
k : Precautions related to work safety
a : Know-how or precautions for work
6 : Amount of oil or coolant to be
drained.
WA1200-6 50-5
Coating materials list
Coating materials list 50-6

(Rev. 2011.06)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassem-
bly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate-
Komatsu code Part number Capacity Container Main features and applications
gory
q Use to prevent rubber gaskets, rubber cushions,
LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropyl-
20 g Polyethyl-
ene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050 (2 pcs. con- ene con-
ber, metal, and non-metal parts which require
tained) tainer
immediate and strong adhesion.
Polyethyl-
q Features: Resistance to heat and chemicals
LT-2 09940-00030 50 g ene con-
q Use to fix and seal bolts and plugs.
tainer
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Polyethyl-
LT-4 790-129-9040 250 g ene con- q Use to seal plugs for blank holes.
tainer
Adhesive
Holtz MH 705 790-126-9120 75 g Tube q Heat-resistant seal used to repair engines

q Instanetaneous adhesive
Polyethyl-
q Curing time: From 5 sec. to 3 min.
Three Bond 1735 790-129-9140 50 g ene con-
q Use mainly to bond metals, rubbers, plastics,
tainer
and woods.
q Instanetaneous adhesive
Polyethyl- q Quick-curing type (max. strength is obtained af-
Aron-alpha 201 790-129-9130 2g ene con- ter 30 minutes)
tainer q Use mainly to bond rubbers, plastics, and met-
als.
q General-purpose instantaneous adhesive with
excellent resistance to heat and impact
LOCTITE 499 428-99-80070 20 g Tube
q Use on the bushing mounting faces of axle sup-
ports.
Polyethyl- q Features: Resistance to heat and chemicals
LOCTITE 648-50 79A-129-9110 50 cc ene con- q Use for fitted portions exposed to high tempera-
tainer tures.
q Use to seal various threaded portions, pipe
Polyethyl-
joints, and flanges.
LG-5 790-129-9080 1 kg ene con-
q Use to seal taper plugs, elbows, and nipples for
tainer
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal threaded portions and flange surface
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
q Features: Silicon-based, heat and cold-resistant,
LG-8
419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant
Three Bond 1207B
q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear
LG-9 top seal which is not clamped by bolts, gaps in
790-129-9310 200 g Tube
Three Bond 1206D the weld which must be caulked, etc.
q Can be coated with paint.
50-6 WA1200-6
Cate-
gory
q Use as lubricant or sealant when the radiator
LG-10
790-129-9320 200 g Tube hoses are put on.
Three Bond 1206E
Liquid gasket
q Can be coated with paint.

q Feature: Can be used together with solid gas-
LG-11 kets.
790-129-9330 200 g Tube
Three Bond 1121 q Use for covers of the transmission case and
steering case etc.
Three Bond 1211 790-129-9090 100 g Tube q Liquid gasket used to repair engine
q Use to prevent galling and seizure of press-fitted
Molybdenum disulphide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
q Use to lubricate linkages, bearings, etc.
lubricant
q Spray type
q Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from gall-
– 09995-00250 190 g Can
ing.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

pound with metallic super-fine-grain, etc.
Seizure
LC-G
– – Can q Use for the mounting bolt in the high temperature
NEVER-SEEZ
area of the exhaust manifold and the turbocharg-
er, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
q Lithium grease with extreme pressure lubrication
G0-LI(*) SYGA-160CNLI Various Various
performance, general purpose type.
*: For cold regions SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
q Use for parts under heavy load.
Caution:
Molybdenum disul- SYG2-400M 400 g × 10 Bel-
q Do not use this grease for rolling bearings like
phide grease SYG2-400M-A 400 g × 20 lows-type
swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg container
q Use this grease for work equipment pins only
Can
when installing them, but do not use it afterward.
Grease
SYG2-400T-A
q Higher seizure resistance, heat resistance and
Hyper White SYG2-16CNT Bel-
water resistance than molybdenum disulphide
G2-T SYG0-400T-A 400 g lows-type
grease.
G0-T(*) (*) 16 kg container
q Not conspicuous on machine since color is
*: For cold regions SYG0-16CNT Can
white.
(*)
Biog rease SYG2-400B
G2-B SYGA-16CNB Bel-
q Since this grease is biodegradable in short peri-
G2-BT(*) SYG2-400BT 400 g lows-type
od, it has less impact on microorganisms, ani-
*: For use at high (*) 16 kg container
mals, and plants.
temperature and SYGA-16CNBT Can
under high load (*)
q Feature: Silicone grease with wide usable tem-
perature range, high resistance to thermal-oxi-
G2-S
– 200 g Tube dative degradation and performance to prevent
Three Bond 1855
deterioration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
WA1200-6 50-7
Cate-
gory
q Feature: Urea (organic system) grease with heat
Grease
G2-U-S resistance and long life. Enclosed type.

427-12-11871 2 kg Can
ENS grease q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
Glass q Use to accelerate hardening of instantaneous
LOCTITE 712 428-99-80080 100 ml
container adhesive.
q Use as primer for painted cab sheet metal
SUNSTAR
Glass surface.
PAINT PRIMER 20 ml
container (Effective period: four months after manu-
580 SUPER
417-926-3910 facture)
SUNSTAR q Use as primer for cab glass surface.
Glass
GLASS PRIMER 20 ml (Effective period: four months after manu-
container
580 SUPER facture)
q Use as primer for painted cab sheet metal
Primer
SUNSTAR
Glass surface.
PAINT PRIMER 22M-54-27230 20 ml
container (Effective period: four months after manu-
435-95
facture)
q Use as primer for black ceramic-coated
SUNSTAR glass surface and for hard polycarbon-
GLASS PRIMER 22M-54-27240 150 ml Steel can ate-coated surface.
435-41 (Effective period: four months after manu-
facture)
For adhered window glass
SUNSTAR q Use as primer for sash (Almite).

Glass
PRIMER GP-402 22M-54-27250 20 ml (Effective period: four months after manu-
container
for sash facture)
q Use “S" in high-temperature season and
SUNSTAR
Polyethyl- “W" in low-temperature season as adhe-
PENGUINE SEAL
417-926-3910 320 ml ene con- sive for glass.
580 SUPER "S" or
tainer (Effective period: four months after manu-
"W"
facture)
Adhesive
Sikaflex 256HV Polyethyl- q Use as adhesive for glass.

manufactured by 20Y-54-39850 310 ml ene con- (Effective period: six months after manu-
Sika Japan tainer facture)
Ecocart
SUNSTAR q Use as adhesive for glass.
(Special
PENGUINE 22M-54-27210 320 ml (Effective period: six months after manu-
con-
SUPER 560 facture)
tainer)
SUNSTAR Polyethyl- q Use to seal joints of glass parts.
PENGUINE SEAL 417-926-3920 320 ml ene con- (Effective period: four months after manu-
Caulking material
No. 2505 tainer facture)

Polyethyl- q Use to seal front window.
SEKISUI SILI-
20Y-54-55130 333 ml ene con- (Effective period: six months after manu-
CONE SEALANT
tainer facture)
q Use to seal joint of glasses.
GE TOSHIBA SILI-
Cartridge Translucent white seal.
CONES 22M-54-27220 333 ml
(Effective period: 12 months after manu-
TOSSEAL381
facture)
50-8 WA1200-6
Special tool list
Special tool list 50-9
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity:
t --- Special tools that cannot be substituted and should always be used (installed)
q --- Special tools that will be very useful if available and are substitutable with tools available on the
market
a New/Redesign:
N .............Tools newly developed for this model. They have a new part number respectively.
R .............Tools made available by redesigning the existing tools which were developed for other models.
Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank --- Tools that are already used on other models and are usable for this model, too, without any modi-
fication
a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketch-
es of special tools")
a Tool part No. SMT QQQ-QQQ means that the tool is to be made locally and not specified as a spe-
cial tool (i.e., the price is not set). Therefore, such a tool is not available from Komatsu Ltd.
New/redesign
Necessity
Sketch
Sym-
Q'ty
Work Part No. Part name Detail of work, remarks
bol
1 SMT-890-5200 Lifting tool assembly t 1

Sling for engine assembly
1-1 SMT-890-5210 q Frame t 1 Q
Commercially (S-SLSL f10
1-2 q Single sling q 4
Removal and installa- available , L = 1.5 m, manufactured by
A
tion of engine assembly KITO)
Commercially (GD-4N f12.5x4
1-3 q Quad sling q 1
available , L = 2 m, manufactured by
KITO)
1 SMT-890-1830 Spacer t 1 Q
Press fit of bearing
2 SMT-890-1710 Sleeve t 1 Q
3 SMT-890-1810 Push tool t 1 Q
Disassembly and 790-201-2100 Push tool t 1 Press fit of oil seal
B 4
assembly of damper 790-201-2390 q Plate t 1
Sling for damper cover and
5 SMT-890-5010 Lifting tool t 1 Q
damper assembly
6 790-101-3701 Gear puller t 1 Removal of spacer
SMT-890-1200 Assembly drawing t 1 Q
1 SMT-890-1210 q Socket t 1 Q Press fit of retainer oil seal
SMT-890-1220 q Guide t 1 Q
2 SMT-890-1230 Socket t 1 Q Press fit of bearing
3 SMT-890-1240 Test/J t 1 Q Preload adjustment of input
Disassembly and
SMT-890-1250 Test/J t 1 Q gear bearing
assembly of modulation
Removal and installation of
clutch, and disassem- C 4 SMT-890-1310 Wrench t 1 Q
modulation clutch piston nut
bly and assembly of
SMT-890-5600 Assembly drawing t 1 N Q
PTO and transfer
SMT-890-5610 q Gear t 1 N Q
5 SMT-890-5620 q Shaft t 1 N Q Preload adjustment of input
SMT-890-5630 q Carburetor t 1 N Q gear bearing
SMT-890-5640 q Plate t 1 N Q
6 SMT-890-5710 Test jig t 1 N Q
WA1200-6 50-9
Special tool list
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
Press fit of transmission front

1 SMT-890-1410 Socket t 1 Q
housing bearing
SMT-890-1500 Assembly drawing t 1 Q
Press fit of transfer output
2 SMT-890-1510 q Socket t 1 Q
shaft oil seal
Disassembly and Press fit of transfer output
assembly of transmis- shaft dust seal
sion, disassembly and Press fit of transfer output
assembly of transfer, D shaft coupling cover
and disassembly and Press fit of transfer output
assembly of parking shaft bearing
brake Support for transfer output
shaft
Socket (Width across Removal and installation of
7 790-302-1280 t 1
flats: 55 mm) transfer coupling bolt
Insertion of R, and F and 3rd
8 SMT-890-4100 Guide t 1 Q
clutch carrier pinion shafts
790-314-1000 Puller t 1
790-101-4000 Puller t 1
790-101-1102 Pump t 1
SMT-890-2170 q Plate t 1 Q
1 SMT-890-2180 q Bolt t 1 Q Press fit of bearing
01643-33690 q Washer t 2
01580-03629 q Nut t 2
Removal and installa- SMT-890-2210 q Guide t 1 Q
K
tion of center hinge pin SMT-890-2220 q Guide t 1 Q
791-775-1140 q Bolt t 1
01643-33080 q Washer t 2
01582-03024 q Nut t 2
790-101-4000 Puller t 1
790-101-1102 Pump t 1
SMT-890-2300 Push tool t 1 Q
SMT-890-2310 q Sleeve t 1 Q
SMT-890-2320 q Sleeve t 1 Q Press fit of bushing
2 SMT-890-2330 q Plate t 1 Q (In common with K1)
SMT-890-2210 q Guide t 1 Q (In common with K1)
791-775-1140 q Bolt t 1
01643-33080 q Washer t 2
01532-03024 q Nut t 2
Removal and installa- SMT-890-2420 Push tool t 1 Q
K 3 Press fit of dust seal
tion of center hinge pin SMT-890-2430 Push tool t 1 Q
50-10 WA1200-6
Special tool list
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
793T-870-141
1 stand q 1 Q Support for front frame
0
793T-870-142
2 stand q 1 Q Support for rear frame
0
793T-870-143
Removal and installa- 3 stand q 1 Q Support for rear frame
0
tion of front and rear L
Locking of axle mount bolt
axles 4 SMT-890-5020 Plate q 1 Q
(for front axle)
5 SMT-890-5030 Plate q 1 Q
(for rear axle, front)
6 SMT-890-5040 Plate q 1 Q
(for rear axle, rear)
792-340-1120 Nut wrench t 1 Removal and installation of
1
796-550-1310 Wrench t 1 sleeve nut
792-525-3000 Micrometer t 1
Preload adjustment of side
2 790-425-1670 Adapter t 1
bearing
790-425-1660 Wrench t 1
SMT-890-3100 Tool assembly t 1 Q
SMT-890-3110 q Cylinder t 1 Q
Preload adjustment of hub
Disassembly and 3 SMT-890-3120 q Piston t 1 Q
bearing
SMT-890-3130 q Shaft t 1 Q
assembly of differential,
SMT-890-3140 q Plate t 1 Q
and disassembly and J
SMT-890-5100 Handle assembly t 1 Q
assembly of final drive
SMT-890-5110 q Handle t 1 Q
and brake SMT-890-5120 q Flange t 1 Q
04025-00850 q Parallel pin t 1
4 q Hexagon socket head Installation of axle shaft
01252-61675 t 2
bolt
q Hexagon socket head
01252-62045 t 1
bolt
01580-31613 q Nut t 1
5 SMT-890-1910 Installer t 1 Q Installation of floating seal
WA1200-6 50-11
Special tool list
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
SMT-890-5480 Bolt q 2 Q Removal of work equipment

1 pin
SMT-890-5491 Nut q 2 Q
(for f180 pins)
2 SMT-890-5460 Bolt q 2 Q Removal of work equipment
pin
SMT-890-5471 Nut q 2 Q
(for f240 and 280 pins)
SMT-890-5300 Push puller assembly q 1 Q
SMT-890-5310 q Plate q 1 Q
Installation of work equipment
SMT-890-5320 q Guide bar q 2 Q
pin
SMT-890-5330 q Flange nut q 1 Q
SMT-890-5340 q Push bolt q 1 Q
3 (P-16) (Commercially avail-
SMT-890-5350 q Leveling pad q 1 Q
able)
For pin mounting bolt hole of
SMT-890-5360 q Adapter q 2 Q
30 mm in diameter (*1)
For pin mounting bolt hole of
SMT-890-5370 q Adapter q 2 Q
24 mm in diameter (*2)
SMT-890-5050 Plate q 1 Removal of collar
4
SMT-890-5070 Bolt q 4 (for f180 and 240 pins)
SMT-890-5060 Plate q 1 Q Removal of collar
5
SMT-890-5070 Bolt q 4 Q (for f280 pins)
Removal and installa- Collar stopper plate for f180
tion of work equipment T 10 42C-98-11320 Plate q 1 Q
pin
assembly Collar stopper plate for f240
11 42C-98-11330 Plate q 1 Q
pin
Collar stopper plate for f280
12 42C-98-11340 Plate q 1 Q
pin
Collar tap bolt for pins of any
13 01017-51245 Bolt q 2
size
Collar stopper plate tap bolt
01011-81265 Bolt q 2 (for joint of lift arm and
bucket)
01011-81250 Bolt q 2 (for joint of bucket link and
bucket)
14
01011-81230 Bolt q 2 (for joint of lift arm and bell
crank)
01010-81230 Bolt q 2 (for joints other than the
above three joints)
Fixing plate for press fit of
15 42C-98-11350 Plate q 1 Q
bushing
*1 (For pin mounting bolt hole of 30 mm in diameter)
Lift arm tip and bucket, bell rank center, lift cylinder rod, lift cylinder bottom, lift arm and front frame
*2 (For pin mounting bolt hole of 24 mm in diameter)
Bucket link and bucket, bucket link and bell crank, bucket cylinder rod, bucket cylinder bottom
50-12 WA1200-6
Special tool list
New/redesign
Necessity
Sketch
Sym-
Q'ty
bol
Disassembly and assembly of

2 790-502-1003 Cylinder repair stand q 1
hydraulic cylinder
3 790-720-1000 Expander q 1 Installation of piston ring
(For steering cylinder)
Disassembly and 796-720-1720 Ring q 1
(Piston diameter: 225 mm)
assembly of hydraulic U 07281-02429 Clamp q 1 (For lift cylinder)
cylinder 4 (Piston diameter: 360 mm)
796-720-1730 Ring q 1
(For bucket cylinder)
07281-03209 Clamp q 1 (Piston diameter: 300 mm)
Disassembly and assembly of
5 790-102-3902 Wrench q 1
steering cylinder piston
WA1200-6 50-13
Sketches of special tools
Sketches of special tools 50-14

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A1-1 Frame 50-14
B1 Spacer 50-14
50-14 WA1200-6
B2 Sleeve 50-15
B3: Push tool 50-15
WA1200-6 50-15
B5 Lifting tool 50-16
C1 (1/3) Assembly drawing 50-16
50-16 WA1200-6
C1 (2/3) Socket 50-17
C1 (3/3) Guide 50-17
WA1200-6 50-17
C2 Socket 50-18
C3 (1/2) Test jig 50-18
50-18 WA1200-6
C3 (2/2) Test jig 50-19
C4. Wrench 50-19
WA1200-6 50-19
C5 (1/5) Assembly drawing 50-20
C5 (2/5) Gear 50-20
50-20 WA1200-6
C5 (3/5) Shaft 50-21
C5 (4/5) Cap 50-21
WA1200-6 50-21
C5 (5/5) Plate 50-2
C6 Test jig 50-2
50-22 WA1200-6
D1 Socket 50-23
D2 (1/3) Assembly drawing 50-23
WA1200-6 50-23
D2 (2/3) Socket 50-24
D2 (3/3) Guide 50-24
50-24 WA1200-6
D3 Socket 50-25
D4 Socket 50-25
WA1200-6 50-25
D5 Socket 50-26
D6 Socket 50-26
50-26 WA1200-6
D8 Guide 50-27
K1 (1/11) Push tool 50-27
WA1200-6 50-27
K1 (2/11) Guide 50-28
K1 (3/11) Guide 50-28
50-28 WA1200-6
K1 (4/11) Guide 50-29
K1 (5/11) Guide 50-29
WA1200-6 50-29
K1 (6/11) Guide 50-30
K1 (7/11) Guide 50-30
50-30 WA1200-6
K1 (8/11) Plate 50-31
K1 (9/11) Bolt 50-31
WA1200-6 50-31
K1 (10/11) Guide 50-32
K1 (11/11) Guide 50-32
50-32 WA1200-6
K2 (1/4) Push tool 50-3
K2 (2/4) Sleeve 50-3
WA1200-6 50-33
K2 (3/4) Sleeve 50-34
K2 (4/4) Plate 50-34
50-34 WA1200-6
K3 (1/4) Push tool 50-35
K3 (2/4) Push tool 50-35
WA1200-6 50-35
K3 (3/4) Push tool 50-36
K3 (4/4) Push tool 50-36
50-36 WA1200-6
L1 Stand 50-37
L2 Stand 50-37
WA1200-6 50-37
L3 Stand 50-38
L4 Plate 50-38
50-38 WA1200-6
L5 Plate 50-39
L6 Plate 50-39
WA1200-6 50-39
J3 (1/5) Tool assembly 50-40
J3 (2/5) Cylinder 50-40
50-40 WA1200-6
J3 (3/5) Piston 50-41
J3 (4/5) Shaft 50-41
WA1200-6 50-41
J3 (5/5) Plate 50-42
J4 (1/3) Handle assembly 50-42
50-42 WA1200-6
J4 (2/3) Handle 50-43
J4 (3/3) Flange 50-43
WA1200-6 50-43
J5 Installer 50-4
50-44 WA1200-6
T1 (1/2) Bolt 50-45
T1 (2/2) Nut 50-45
WA1200-6 50-45
T2 (1/2) Bolt 50-46
T2 (2/2) Nut 50-46
50-46 WA1200-6
T3 (1/8) Push puller assembly 50-47
T3 (2/8) Plate 50-47
WA1200-6 50-47
T3 (3/8) Guide bar 50-48
T3 (4/8) Flange nut 50-48
50-48 WA1200-6
T3 (5/8) Push bolt 50-49
T3 (6/8) Leveling pad 50-49
WA1200-6 50-49
T3 (7/8) Adapter (for 30 mm) 50-50
T3 (8/8) Adapter (for 24 mm) 50-50
50-50 WA1200-6
T5 (1/2) Plate 50-51
T5 (2/2) Bolt 50-51
WA1200-6 50-51
T10 Plate 50-52
T11 Plate 50-52
50-52 WA1200-6
T12 Plate 50-53
T15 Plate 50-53
WA1200-6 50-53
Flushing procedure
Flushing procedure for brake circuit
Flushing procedure 50-54

Flushing procedure for brake circuit 50-54
Selection of flushing pattern

Pattern Contamination level
When replacing a damaged internal part of a
A
hydraulic component
When flushing a hydraulic circuit that has
failed in the past but is working properly
B
When flushing a hydraulic circuit that has not
failed in the past and is working properly
Work outline for each pattern

Pattern
No. Work item
A B
Cleaning of each hydraulic component
q Hydraulic pump Q –
q Valves Q –
1
q Hydraulic tank Q –
q Brake oil cooler Q –
q Hydraulic tubes and hoses Q –
2 Flushing of hydraulic circuits Q Q
3 Replacement of hydraulic oil Q Q
4 Replacement of element Q Q
50-54 WA1200-6
Flushing procedure
Parts used for flushing

Pattern
No. Work item Part No.
A B
07063-41187 1 1
1 Flushing element
07063-51035 1 1
208-60-61180 1 1
2 Standard element
07063-51035 1 1
Filter and bypass cir-
3 21T-60-13680 1 1
cuit closing plate
4 In-line filter strainer 421-43-27920 1 1
5 O-ring 07002-25234 1 1
11 Breather 566-60-15361 1 1
12 Brake oil cooler 42C-03-15110 1 –
WA1200-6 50-55
Flushing procedure
Flushing procedure 50-56

(Flushing pattern A) 50-56
1. Check that the following components are disas-
sembled, cleaned, and re-installed.
1) Replace the parts that caused a problem with
new ones.
2) Disassemble, clean, and assemble each
hydraulic valve.
1] When the brake pump is damaged
q Brake valves (right and left) (2) and
(11)
q Accumulator (10)
q Accumulator charge valve (14)
q Accumulator check valves (front and
rear)
q Parking brake emergency operation
valve
q Parking brake solenoid valve (16)
q Slack adjusters (front and rear) (5)
and (13)
q Wheel cylinder (for each of the four
wheels)
q Brake pump strainer
q Brake tank interconnection strainer
q Hydraulic tank (8)
a Replace the following parts with new
ones if flushing equipment is not avail-
able.
q Brake valves (right and left)
q Accumulator charge valve
q Parking brake emergency operation
valve
q Parking brake solenoid valve
a Slack adjusters and wheel cylinders
do not require cleaning if broken frag-
ments are not circulated.
2] When cooling pump (6) is damaged
q Brake oil cooler (17)
q Relief valve for oil cooler
q Brake disc (for each of the four
wheels)
a If the cooling pump is damaged se-
verely, replace the brake oil cooler
with a new one.
3) Remove the hydraulic hoses and hydraulic
tubes from the machine and clean them.
4) Install the disassembled, cleaned, and
assembled parts to the machine.
50-56 WA1200-6
Flushing procedure
2. Preparation for flushing 3) Start and run the engine at low idle. After the
1) Replace filter elements (F1) and (F2) in the brake oil pressure warning lamp goes off,
brake oil tank with flushing elements. "press" and "release" the brake pedal repeat-
2) Replace bypass valves (B1) and (B2) with edly for 10 minutes at an interval of 3
bypass circuit closing plates. seconds.
4) Stop the engine and "press" and "release"
the brake pedal repeatedly at an interval of 3
seconds until accumulator pressure is
relieved.
5) Start and run the engine at 1,500 rpm. After
the brake oil pressure warning lamp goes off,
"press" and "release" the brake pedal repeat-
edly for 10 minutes at an interval of 3
seconds.
relieved.
7) Start and run the engine at high idle. After the
brake oil pressure warning lamp goes off,
seconds.
relieved.
4. Reinstallation
1) Replace the flushing elements in the brake
oil tank with the new standard elements.
2) Remove the bypass circuit closing plates
from the filter and install the bypass valves.
3) Replace brake pump strainer (5) with a new
q Replace bypass valves (B1) and (B2) with one.
bypass circuit closing plates.
q Replace filter elements (F1) and (F2) with
flushing elements.
q Clean the Br and St parts.
3) Add hydraulic oil (new oil) to the specified
level in the brake oil tank.
5 Brake oil tank:
315 l
3. Perform flushing in the following procedure.

1) Start and run the engine at low idle until the
hydraulic oil temperature reaches 40 to
50 °C. Do not operate the brake during this
step.
the brake pedal repeatedly at an interval of 3 4) Add hydraulic oil (new oil) to the specified
seconds until accumulator pressure is level.
relieved.
WA1200-6 50-57
Flushing procedure
(Flushing pattern B) 50-58 3. Perform flushing in the following procedure.

1. Drain the oil from the hydraulic tank. 1) Start and run the engine at low idle until the
2. Preparation for flushing 50 °C. Do not operate the brake during this
1) Replace filter elements (F1) and (F2) in the step.
brake oil tank with flushing elements. 2) Stop the engine and "press" and "release"
2) Replace bypass valves (B1) and (B2) with the brake pedal repeatedly at an interval of 3
bypass circuit closing plates. seconds until accumulator pressure is
relieved.
3) Start and run the engine at low idle. After the
seconds.
relieved.
5) Start and run the engine at 1,500 rpm. After
the brake oil pressure warning lamp goes off,
seconds.
relieved.
7) Start and run the engine at high idle. After the
seconds.
relieved.
qReplace bypass valves (B1) and (B2) with 4. Check of element
bypass circuit closing plates. Perform one cycle of steps 1) to 8) and check the
q Replace filter elements (F1) and (F2) with
element. If the element is contaminated, clean it
flushing elements. and perform one flushing cycle again.
q Clean the Br and St parts.
level in the brake oil tank.
5 Brake oil tank:
315 l
50-58 WA1200-6
Flushing procedure
5. Reinstallation
1) Replace the flushing elements in the brake
oil tank with the new standard elements.
2) Remove the bypass circuit closing plates
from the filter and install the bypass valves.
3) Replace brake pump strainer (5) with a new
one.

level.
WA1200-6 50-59
Flushing procedure
Flushing procedure for work equipment and steering circuit
Flushing procedure for work equipment and steering circuit 50-60
Selection of flushing pattern

Pattern Contamination level
When replacing a damaged internal part of a
A
hydraulic component
When flushing a hydraulic circuit that has
B
failed in the past but is working properly
When flushing a hydraulic circuit that has not
C
failed in the past and is working properly
Work outline for each pattern
Pattern
No. Work item
A B C
Cleaning of each hydraulic compo-
nent
q Hydraulic pump Q – –
q Valves Q – –
1
q Hydraulic cylinder Q – –
q Hydraulic tank Q – –
q Hydraulic oil cooler Q – –
q Hydraulic tubes and hoses Q – –
Short-circuit flushing of hydraulic cir-
cuits
2 q Lift arm cylinder circuit Q – –
q Bucket cylinder circuit Q – –
q Steering cylinder circuit Q – –
3 Replacement of hydraulic oil Q Q –
4 Replacement of element Q Q Q
50-60 WA1200-6
Flushing procedure
Parts used for flushing

Pattern
No. Work item Part No.
A B C
1 Flushing element 07063-41187 3 – –
2 Standard element 208-60-61180 3 3 3
F2 2 2 –
3 Short-circuit flange
F3 4 4 –
4 PPC element 209-60-12840 2 2 2
Filter and bypass cir-
5 21T-60-13680 3 3 3
cuit closing plate
6 In-line filter strainer 207-60-61250 2 2 2
7 In-line filter strainer 209-60-63210 6 6 6
O-ring
8 07000-22060 4 4 –
(bucket cylinder)
O-ring
9 07000-22060 8 8 –
(lift arm cylinder)
O-ring
10 07000-22048 8 8 –
(steering cylinder)
11 Suction strainer 427-60-15320 1 1 –
12 Hydraulic oil cooler 1 – –
Note: Nos. 3, 8, 9, and 10 are used only for short-circuit
flushing.
(They must be removed when flushing is finished.)
WA1200-6 50-61
Flushing procedure
Flushing pattern A 50-62 2. Preparation for flushing

1. Check that the following components are disas- 1) Replace filter element (2) in the hydraulic
sembled, cleaned, and re-installed. tank with a flushing element.
1) Replace the parts that caused a problem with 2) Replace bypass valve (3) with a bypass
new ones. circuit closing plate.
2) Disassemble, clean, and assemble each 3) Replace suction strainer (4) with a new one.
hydraulic valve.
q Control valve (three valves)
q PPC valve
q PPC relief valve
q Steering demand valve
q Hydraulic tank
q Breather
q Hydraulic oil cooler line cold relief valve
q Emergency steering diverter valve
3) Disassemble, clean, and assemble each
hydraulic cylinder.
q Lift arm cylinder (two cylinders)
q Bucket cylinder (two cylinders)
q Steering cylinder (two cylinders)
4) Replace hydraulic oil cooler (1) with a new
one.
4) Connect the inlet and outlet hoses of the

hydraulic cylinders by using tools F2 and F3
5) Remove the hydraulic hoses and hydraulic (short-circuit flanges) to short-circuit the
tubes from the machine and clean them. hydraulic circuit.
6) Install the disassembled, cleaned, and 5) Add hydraulic oil to the specified level in the
assembled parts to the machine. hydraulic tank.
5 Hydraulic tank:
1200 l
3. Perform flushing according to the following
procedure.
50 °C. Do not operate the work equipment
and steering during this step.
2) Run the engine at a medium speed for 20
minutes.
a Do not operate the work equipment and
steering during this step.
50-62 WA1200-6
Flushing procedure
3) Run the engine at the full speed and operate 5) Add hydraulic oil to the specified level.
the levers according to the following proce- 6) Replace in-line filter strainers (6) and (7) with
dure. new ones.
1] Move the steering lever to the right and
hold it there for 2 minutes.
2] Move the steering lever to the left and
3] Move the lift arm lever to RAISE and hold
it there for 2 minutes.
4] Move the lift arm lever to LOWER and
5] Move the bucket lever to TILT and hold it
there for 2 minutes.
6] Move the bucket lever to DUMP and hold
4) Repeat steps 1) to 6) 5 times or more.
4. Reinstallation
1) Remove the short-circuit flanges from all
cylinder circuits and install the hoses to each
cylinder.
q Lift arm cylinder (two cylinders)
q Bucket cylinder (two cylinders)
q Steering cylinder (two cylinders)
2) Replace the flushing element in the hydraulic
tank with a new standard element.
3) Remove the filter bypass circuit closing plate
and install the bypass valve.
4) Replace PPC element (5) with a new one.
WA1200-6 50-63
Flushing procedure
Flushing pattern B 50-64 5. Reinstallation

1. Drain the oil from the hydraulic tank. 1) Remove the short-circuit flanges from all
2. Remove the strainer of the hydraulic tank. cylinder circuits and install the hoses to each
3. Preparation for flushing cylinder.
1) Replace filter element (2) in the hydraulic q Lift arm cylinder (two cylinders)
tank with a flushing element. q Bucket cylinder (two cylinders)
2) Replace bypass valve (3) with a bypass q Steering cylinder (two cylinders)
circuit closing plate. 2) Replace the flushing element in the hydraulic
3) Connect the inlet and outlet hoses of the tank with a new standard element.
hydraulic cylinders by using tools F2 and F3 3) Remove filter bypass circuit closing plates
(short-circuit flanges) to short-circuit the and install the bypass valve.
hydraulic circuit. 4) Replace PPC element (5) with a new one.
4) Add hydraulic oil to the specified level in the
hydraulic tank.
5 Hydraulic tank:
1200 l
procedure.
minutes.
3) Run the engine at the full speed and operate
the levers according to the following proce-
dure.
1] Move the steering lever to the right and
2] Move the steering lever to the left and
3] Move up the lift arm lever to RAISE and
hold it for 2 minutes.
4] Move the lift arm lever to LOWER and
5] Move the bucket lever to TILT and hold it
there for 2 minutes.
6] Move the bucket lever to DUMP and hold
4) Repeat steps 1) to 6) 5 times or more.
50-64 WA1200-6
Flushing procedure
Flushing pattern C 50-65

1. Preparation for flushing
1) Replace filter element (2) in the hydraulic
tank with a flushing element.
2) Replace bypass valve (3) with a bypass
circuit closing plate.
3) Add hydraulic oil to the specified level.
procedure.
minutes.
5) Replace in-line filter strainers (6) and (7) with
new ones.
3) Run the engine at the full speed and operate
the levers according to the following proce-
dure.
1] Move the steering lever to the right end
and then to the left end. Repeat this oper-
ation ten times.
2] Move the lift arm lever to RAISE end and
then to LOWER end. Repeat this opera-
tion ten times.
3] Move the bucket lever to TILT end and
then to DUMP end. Repeat this operation
ten times.
4) Check of element
Perform one cycle of steps 1) to 3) and check
the element. If the element is contaminated,
clean it and perform one flushing cycle again.
3. Reinstallation
1) Replace the flushing element in the hydraulic
tank with a new standard element.
2) Remove the filter bypass circuit closing plate
and install the bypass valve.
3) Replace PPC element (5) with a new one.
4) Add hydraulic oil to the specified level in the
hydraulic tank.
WA1200-6 50-65
Air bleeding procedure
Bleeding air from brake circuit
Air bleeding procedure 50-6

Bleeding air from brake circuit 50-6
Bleeding air from wheel brake circuit 50-6
a If a hose in the brake circuit is disconnected for

removing or installing a brake valve or an axle,
breed air from the circuit according to the follow-
ing procedure.
k Apply the parking brake and chock the
wheels.
k Never bleed air from the slack adjuster while
the engine is running, because the drive
shaft is rotating.
1. Start the engine and accumulate pressure in the
accumulator.
(This takes approximately 30 seconds with the
engine running at high idle.)
2. Start the engine and connect one end of a vinyl
hose to the bleeder and insert the other end into
a container.
3. Depress the brake pedal and then loosen the
bleeder screw to bleed air. Return the brake
pedal slowly after tightening the bleeder screw.
a This work must be done by two workers. One
worker depresses the brake pedal and the
other bleeds air by loosening the bleeder
screw.
a Use the L.H. brake pedal.
a Add brake oil to keep the tank full.
4. Repeat this operation until the oil flowing through
the vinyl hose becomes free from bubbles. Then
depress the pedal fully and tighten the bleeder
screw while the oil is flowing.
5. Bleed air from the slack adjuster on the other
side and bleeder (1) on each wheel by using the
same procedure.
a If the pressure in the accumulator drops, start
the engine to charge the accumulator.
a After finishing bleeding air, run the engine at
low idle and check the oil level in the brake oil
tank. If the level is low, add oil.
a After air bleeding is completed, perform
"Testing wheel brake performance".
50-66 WA1200-6
Bleeding air from brake circuit
Bleeding air from brake pump circuit 50-67 6. Check again the oil level in the brake oil tank.
Add oil if necessary.
1. Check that the oil level in the brake oil tank is 7. Depress the brake pedal to check that the brake
HIGH. circuit operates normally and that the brake
2. Bleed air from the wheel circuit. For details, see charge cut-in and cut-out pressures are normal.
"Bleeding air from wheel brake circuit".
3. Loosen locknut (2) of the R3 main relief valve of
accumulator charge valve (1), then return main
relief valve (3) so that slight pressure is applied
to the valve spring.
a Put a position mark on each of locknut (2) of
the R3 main relief valve and main relief valve
(3) by using a marker pen so that they are re-
turned to the original positions.
4. Start the engine and use the Pm Clinic menu of

VHMS to display the brake oil pressure on the
screen.
5. Keep the engine running for 5 minutes. When
the brake oil pressure becomes normal, return
R3 main relief valve (3) of the accumulator
charge valve to the original position and tighten
lock nut (2).
WA1200-6 50-67
Bleeding air from piston pump
Bleeding air from piston pump 50-68
a When the oil in the hydraulic tank is replaced, 2. Bleeding air from piston pump
when the piston pump is replaced, or when pip- 1) Loosen air bleeding plugs (1), (2), (3), and (4)
ing of the piston pump is removed, bleed air ac- on the top of the tube on the suction side of
cording to the following procedure to prevent the piston pump.
pump seizure. 2) Pressurize the hydraulic tank by using an air
1. Preparation compressor.
1) Remove plug (5) on the side of the breather k Slowly pressurize the hydraulic tank
and connect an air-pressurization coupler so that the oil does not blow out
and an air hose. through the plugs.
2) Add oil to the dipstick level (H level) in the 3) When the oil overflows from the plugs and air
tank. (Oil type: EO10-CD) is bled completely, stop the pressurization
and tighten the plugs.
4) Loosen the drain hose fittings (two places on
each pump) in the upper part of the piston
pumps.
5) Pressurize the hydraulic tank by using an air
compressor.
k Slowly pressurize the hydraulic tank
so that the oil does not blow out
through the hose fittings.
6) When the oil overflows from the hose fittings
and air is bled completely, stop the pressur-
ization and tighten the hose fittings.
50-68 WA1200-6
Bleeding air from work equipment circuit and steering circuit
Bleeding air from work equipment circuit and steering circuit 50-69
q Bleeding air from work equipment oil circuit 5. Run the engine at low idle.
a When the hydraulic oil control valve or work 1) Slowly move the lift arm and bucket cylinder
equipment cylinder has been removed and rein- piston rod to the position just before the
stalled, bleed the system of air by following the stroke end.
procedure given below. q Never let the relief valves actuate.
1. Supply the hydraulic tank with oil until the oil q Raise and lower the lift arm and tilt and
level reaches the window of the sight gauge (1). dump the bucket four to five times repeat-
edly.
2) Slowly move the lift arm and bucket cylinder

to the stroke end.
q Raise and lower the lift arm and tilt and
dump the bucket four to five times repeat-
edly.
6. Stop the engine and loosen plugs (1) to (4) to

bleed the hydraulic oil filter case of air.
1) Loosen plugs (1) to (4) slowly to bleed air
from the cases one by one.
2. Add oil 400 l further.
and replace any damaged plug with a new
3. Tighten cap (4).
one.
4. Start and run the engine at low idle for five

minutes.
a (Note) Do not run the engine at high idle. Do
not operate the cylinder with its piston rod
reaching the stroke end before bleeding air
(the cylinder may break).
WA1200-6 50-69
7. Lower the bucket to the ground and check the oil q Bleeding air from steering oil circuit
level. Then, add oil up to the window of the sight a Bleed air from the oil circuit as follows if the
gauge (1). steering valve or steering cylinder are removed
and installed.
1. Supply the hydraulic tank with oil until the oil

level reaches the window of the sight gauge (1).
8. Run the engine at 1,500 rpm and slowly move

the lift arm cylinders and bucket cylinders with
their piston rods come to the stroke ends.
q Raise and lower the lift arm and tilt and dump 2. Add oil of 400 l further.
the bucket four to five times repeatedly.
3. Tighten cap (4).
air. (see No. 6)
10. Repeat the steps described in No. 8 and No. 9

until the air is completely bled.
11. When the air is completely bled, check the oil

level. Add oil until the oil level reaches the
window of sight gauge (1).
4. Start and run the engine at low idle for five

minutes.
a (Note) Do not run the engine at high idle. Do
not operate the cylinder with its piston rod
reaching the stroke end before bleeding air
(the cylinder may break).
50-70 WA1200-6
5. Run the engine at low idle. 8. Run the engine at 1,500 rpm and slowly move
1) Slowly move each cylinder rod back and forth the cylinder piston rods to their stroke ends.
until it comes to 100 mm before the stroke Steer alternately to right and left four or five
end. times.
q Steer alternately to right and left four or 9. Stop the engine, loosen plugs (1) to (4) to bleed
five times. air. (see No. 6)
2) Slowly move each cylinder rod back and forth
to its stroke ends. 10. Repeat the steps described in No. 8 and No. 9
q Never let the relief valves actuate. until the air is completely bled.
q Steer alternately to the right and left four
or five times. 11. When the air is completely bled, check the oil
level. Add oil until the oil level reaches the
6. Stop the engine, loosen plugs (1) to (4), and window of sight gauge (1).
bleed air from the hydraulic oil filter case.
1) Loosen plugs slowly, one by one to bleed air.
and replace any damaged plug with a new
one.

level. Then, add oil up to the window in the sight
gauge (1).
WA1200-6 50-71
Removal and installation of radiator and hydraulic oil cooler assembly

Removal and installation of radiator and hydraulic oil cooler assembly 50-72
Removal 50-72 6. Disconnect two hydraulic oil cooler pipes (5).

k Before performing removal, be sure to imple-
ment "2. Preparatory work", "3. Precautions
during work" in "00 Safety notice".
1. Drain the engine coolant.

6 Coolant:
approx. 540 l
2. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
3. Open grille (1).
4. Disconnect connector (GR6) of harness (2). 7. Disconnect radiator outlet tube (6).
5. Sling radiator guard (3), and remove mounting 8. Disconnect coolant drain hose (7).
bolt (4) to remove the radiator guard. [*1]
4 Radiator guard:
9. Disconnect hose clamp (8).
970 kg
10. Disconnect connector (GR6) of coolant level

sensor harness (9).
11. Remove the three clamps, and disconnect hose

(10).
12. Disconnect hoses (11) and (12).
13. Remove brackets (13) and (14).
50-72 WA1200-6
14. Loosen hose clamps on the radiator side, and

disconnect HTC radiator inlet tube (15), LTC
radiator outlet tube (16), HTC radiator inlet tube
(17), and LTC radiator inlet tube (18). [*2]
15. Remove fan pulley cover (19).
16. Lift and remove fan guard (20).
17. Remove covers (21) on the right and left, and lift
and remove radiator supports (22) on the right
and left. [*3]
18. Sling radiator and hydraulic oil cooler assembly

(23), and remove ten mounting bolts to remove
the assembly. [*4]
4 Radiator and hydraulic oil cooler as-
sembly:
2,900 kg
WA1200-6 50-73
Installation 50-74 2) Fix the baffle assembly with eight mounting

bolts (29).
q perform installation in the reverse order to re-
moval.
q When the radiator assembly is removed, use the

following steps to install the radiator baffles be-
fore installing the radiator guard.
a Adhesive is applied to the sheet in advance,
which is protected using release paper. Remove
the board just before sticking the sheet.
a Degrease and derust the surface on the baffle
plate, to which the sheet is stuck.
1. Bottom of oil cooler

a Perform this step before installing the radia-
tor and oil cooler assembly to the machine.
2. Installing radiator and oil cooler
k
Install the radiator and oil cooler assembly to the
Perform this work on the oil cooler placed
machine.
on the floor. Never perform this work
while slinging the oil cooler.
3. Top face of fan guard
1) Stick sheets (31) and (32) on baffle (30), and
1) Stick sheets (25) to (28) on baffle (24), and
install the baffle assembly to the top face of
install the baffle assembly at the bottom of
the rear oil cooler.
the oil cooler.
2) Fix the baffle assembly with eight mounting
a When sticking each sheet, see the follow-
bolts.
ing figure.
ing figure.
50-74 WA1200-6

install the baffle assembly to the left end of
the top face of rear oil cooler (39).
4) Fix the baffle assembly with three mounting
bolts.
ing figure.

install the baffle assembly to the right end of
the top face of rear oil cooler (39).
6) Fix the baffle assembly with three mounting
bolts.
ing figure.
WA1200-6 50-75
4. Side face of fan guard (1) 9) Install baffle (L.H) (47) to the top of the left
1) Stick sheet (41) on baffle (40), and install the side face of front oil cooler (46).
baffle assembly (LH) to the top of the left side 10)Fix the baffle assembly with five mounting
face of rear oil cooler (39). bolts.
2) Fix the baffle assembly with two mounting 11)Install baffle (L.H) (48) to the bottom of the
bolts. left side face of front oil cooler (46).
3) Stick sheet (43) on baffle (42), and install the 12)Fix the baffle assembly with three mounting
baffle assembly (RH) to the top of the right bolts.
side face of rear oil cooler (39). 13)Stick sheet (50) on baffle (L.H) (49), and
4) Fix the baffle assembly with two mounting install the baffle assembly (L.H) to the center
bolts. of the left side face of front oil cooler (46).
5) Install baffle (LH) (44) on the left side face of a Do not peel the release paper in the range
the rear oil cooler. marked by an asterisk (*) on the sheet ad-
6) Fix the baffle assembly with five mounting hesive surface.
bolts. 14)Fix the baffle assembly with two mounting
7) Install baffle (RH) (45) on the right side face bolts.
of the rear oil cooler. 15)Install baffle (R.H) (51) to the top of the right
a When installing, apply the baffle rubber to side face of front oil cooler (46).
the sheet on the radiator guard side. (See 16)Fix the baffle assembly with five mounting
details of part P in the figure.) bolts.
8) Fix the baffle assembly with five mounting 17)Install baffle (R.H) (52) to the bottom of the
bolts. right side face of front oil cooler (46).
18)Fix the baffle assembly with three mounting
a Prefix "R50-36-" to the number in the fol- bolts.
lowing figure to know the number shown
in the kit number list.
50-76 WA1200-6
19)Stick sheet (54) on baffle (R.H) (53), and

install the baffle assembly (RH) to the center
of the right side face of front oil cooler (46).
a Do not peel the release paper in the range
marked by an asterisk (*) on the sheet ad-
hesive surface.
4) Stick sheets (69) and (70) on plate (68).

ing figure.
5. Bottom of oil cooler (2)

1) Install brackets (55) at the bottom of the rear
oil cooler. (Four places)
5) Install baffle assembly (56) on the baffle

assembly (R.H), aligning the bolt holes.
6) Install the plate on the baffle assembly,
aligning the bolt holes. Then, fix them with
mounting bolts.
a For the installed direction of the baffle as-
2) Stick sheets (57) and (61) on baffle (L.H) sembly and plate, see the following fig-
(56). ure.
ing figure.
3) Stick sheets (63) and (67) on baffle (R.H)

(62).
ing figure.
WA1200-6 50-77
7. Hood (radiator guard)

Stick sheets (76) to (79) at the positions shown
in the figure.
a Stick sheets (76) to (78) at the same posi-
tions on each of right and left.
6. Side face of fan guard (2)

Stick sheets (73) and (75) at the positions shown
in the figure.
[*1]
3 Radiator guard mounting bolts:
490 to 608 Nm {50 to 62 kgm}
[*2]
2 Hose insertion part:
Gasket sealant (Three Bond 1208E)
a Turn the hose clamp 180 degrees when install-
ing it.
[*3]
3 Radiator support mounting bolts:
490 to 608 Nm {50 to 62 kgm}
[*4]
3 Radiator and hydraulic oil cooler mount-
ing bolt:
490 to 608 Nm {50 to 62 kgm}
q Refilling of coolant
Add coolant to the specified level. Run the
engine to circulate the coolant through the
system. Then, check the coolant level again.
50-78 WA1200-6
Removal and installation of engine assembly
Removal and installation of engine assembly 50-79
Special tools 50-79 7. Disconnect hoses (7)and (8).
New/redesign
Necessity
8. Remove brackets (9) and (10).
Sketch
Sym-
Q'ty
Part No. Part name
bol
9. Loosen the hose clamps and remove HTC radi-
ator inlet tube (11), LTC radiator outlet tube (12),
1 SMT-890-5200 Lifting tool assembly t 1 HTC radiator inlet tube (13), and LTC radiator
1-1 SMT-890-5210 q Frame t 1 Q inlet tube (8). [*2]
Commercially
A 1-2 q Single sling q 4
available
Commercially
1-3 q Quad sling q 1
available
Removal 50-79

ment "2. Preparatory work" and "3. Precau-
tions during work" in "00 Safety notice".
1. Drain the engine coolant.

6 Coolant:
approx. 540 l
2. Drain the engine oil. 10. Loosen hose clamps and remove tubes (14) and
6 Engine oil:
(15). [*3]
approx. 260 l
11. Remove fan pulley cover (16).
3. Remove the hood assembly, referring to
"Removal and installation of hood assembly". 12. Remove fan guard (17).
4. Remove the radiator guard, referring to

"Removal and installation of radiator and
hydraulic oil cooler assembly".
5. Remove the bulkhead assembly, referring to

"Removal and installation of bulkhead
assembly".
6. Remove brackets (1), (2), (3), (4), (5), and (6).

[*1]
WA1200-6 50-79
13. Disconnect wiring harness connector E10 (19).

14. Remove cover (20).
15. Loosen bolt (21), loosen belt tension adjustment
bolt (22), and then remove belt (23). [*4]
24. Disconnect wiring harness connector BR1 (43).
16. Loosen hose clamps and disconnect fuel hoses

(26) and (27).
17. Disconnect two hoses (28a) and (28b).
18. Disconnect hose (29).

19. Loosen hose clamps (30) and remove tubes (31)
and (32).
20. Disconnect heater hose (32A).
21. Disconnect suction tube (33).
23. Remove hose clamps (35) and disconnect
hoses (36) and (37).
50-80 WA1200-6
25. Disconnect ground cables (44), (45), and (45a).

26. Disconnect starting motor cables (47) and (48).
29. Disconnect engine drain hose (51).
27. Disconnect heater hose (49).
30. Disconnect engine ground cable (51a).
28. Disconnect centralized wiring harness connector

(50).
WA1200-6 50-81
31. Sling upper drive shaft (52), remove mounting 34. Slowly lift and remove engine assembly (55).
bolts, and then remove the upper drive shaft. a Lift by using tool A1 lifting tool assembly.
[* 5] a When removing the engine assembly, make
a Remove the drive shaft after putting match sure that all the wiring harnesses and piping
marks on the coupling to indicate the mount- are disconnected.
ing position. 4 Engine assembly:
4 Upper drive shaft: 8,600 kg
115 kg
32. Remove four engine front mount mounting bolts

(53). [*6]
33. Remove four engine rear mount mounting bolts
(54). [*7]
50-82 WA1200-6
WA1200-6 50-83
35. Disconnect the damper assembly according to Installation 50-84

1) Sling cover assembly (56), remove mounting q perform installation in the reverse order to the re-
bolts (57), and then remove the cover moval.
assembly. [*8]
4 Cover assembly: [*1]
160 kg 3 Bracket mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
[*2][*3]
2 Connecting portion of hose:
Liquid gasket (Three Bond 1208E)
a Install hose clamps with their joint positions al-
tered by 180 degrees.
[*4]
Adjust the belt tension. For details, see Testing and
adjusting, "Testing and adjusting air conditioner
compressor belt tension".
[*5]
3 Drive shaft mounting bolt:
2) Remove two bolts (59) from the top of
157 to 196 Nm {16 to 20 kgm}
damper assembly (58). Sling the damper
assembly by using eyebolts, remove
[*6]
3
mounting bolts (60), and then remove the
Engine front mount mounting bolt:
damper assembly. [*9]
4 Damper assembly:
824 to 1,030 Nm {84.0 to 105 kgm}
210 kg
[*7]
3 Engine rear mount mounting bolt:
824 to 1,030 Nm {84.0 to 105 kgm}
[*8][*9]
a Do not use grease other than ENS on the damp-
er.
If the grease other than ENS is used, it may
cause unusual heat, premaure deterioration of
the grease, and early deterioration of seal mate-
rial.
Apply or charge ENS grease after thoroughly
removing old grease. Other type of grease must
be completely removed from the grease gun
when using ENS grease.
a Supply grease in the bearing chamber by refer-
ring to "Disassembly and assembly of damper"
q When shaft (61) is removed, install it according
50-84 WA1200-6
1) Apply lubricant to splines "e" of shaft (61) and

leave it for 2 or 3 minutes after application.
Install the shaft when the lubricant is dried.
2 Shaft splines "e":
Molybdenum disulfide based desic-
cating and lubricating agent (LM-P)
2) Supply grease to part "f" when installing shaft
(61) to damper assembly (58).
2 Grease reservoir "f":
100 g (ENS grease)
q ENS grease part number: 427-12-11871
(2 kg can)
2 Cover mounting surface:

Liquid gasket (LG-8)
3 Cover assembly mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
3 Damper assembly mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
q Refilling with oil (engine)

Add oil through the oil filler port to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
WA1200-6 50-85
Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly
Removal and installation of air-cooled torque converter and transmis-

sion, and brake oil cooler assembly 50-86
4. Remove covers (3), (4), (5), (6), (7), and (8).
Removal 50-86 4 Cover (3):
k Before performing removal, be sure to imple- 30 kg
ment "2. Preparatory work" and "3. Precau- 4 Cover (8):
tions during work" in "00 Safety notice". 35 kg
1. Drain the oil from the brake oil tank.

6 Brake oil tank:
approx. 315 l
2. Remove covers (1) and (2).
5. Remove U-bolts and disconnect tubes (9) and

(10).
6. Remove hoses (11), (12), and (13).
3. Remove covers (21) and (22). 7. Remove tube (14) and valve (15) in one piece.
[*1]
8. Remove bracket (16).
50-86 WA1200-6
Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly
9. Remove U-bolts and disconnect tubes (16), (17), Installation 50-87

and (18). q perform installation in the reverse order to the re-
moval.
[*1]
q Pay attention to the direction of the valve when it
is mounted.
a The arrow mark on the valve body must be
oriented in the direction shown in detail P in
the figure below.
10. Sling the oil cooler and fan motor assembly (20),
and then remove right and left cushion mounting
bolts (21) (three pieces on each side) to remove
the oil cooler). [*2]
a When removing the oil cooler and fan motor

assembly (20), make sure that all the wiring
harnesses and piping are disconnected.
4 Oil cooler and fan motor assembly: q Refilling with oil (brake oil tank)
550 kg Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
q Refilling with oil (transmission)

WA1200-6 50-87
Removal and installation of water-cooled torque converter and transmission oil cooler assembly
Removal and installation of water-cooled torque converter and transmis-

sion oil cooler assembly 50-8
5. Sling the torque converter and transmission oil
Removal 50-8 cooler assembly (8) at its right and left parts,
k Before performing removal, be sure to imple- remove mounting bolts (7), and then remove
ment "2. Preparatory work" and "3. Precau- torque converter and transmission oil cooler
tions during work" in "00 Safety notice". assembly while moving them toward the front.
[*1]
1. Drain the engine coolant. 4 Torque convertor and transmission oil
6 Coolant: cooler assembly:
approx. 540 l 285 kg
2. Sling screens (1) and (2), and remove them.
Installation 50-8
3. Disconnect water hoses (3) and (4). q perform installation in the reverse order to the re-
moval.
4. Remove oil tubes (5), (6), and (7).
[*1]
3 Torque converter and transmission oil
cooler mounting bolt:
157 to 196 Nm {16 to 20 kgm}
q Refilling of oil (transmission)

50-88 WA1200-6
Removal and installation of damper assembly
Removal and installation of damper assembly 50-89
Special tools 50-89 6. Sling cover assembly (4), remove mounting

bolts (5), and remove the assembly. [*2]
New/redesign
a Using tool B5 to lower the assembly.
Necessity
4 Cover assembly:
Sketch
Sym
Q'ty
Part No. Part name
bol
160 kg
B 5 SMT-890-5010 Lifting tool t 1 Q
Removal 50-89
1. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
2. Remove the bulkhead assembly. For details,

see "Removal and installation of bulkhead
assembly".
3. Remove all partition covers (1).
7. Remove two bolts (7) at the top of the damper

assembly (6), install eyebolts, and sling the
assembly. Then, remove bolts (8), and remove
the assembly. [*3]
a Using tool B5 to lower the assembly.
4 Damper assembly:
5. Sling drive shaft (3) and remove bolts on the 210 kg
damper side. [*1]
4 Upper drive shaft:
115 kg
WA1200-6 50-89
Removal and installation of damper assembly
Installation 50-90 [*3]

Use tool B5 to install the damper assembly.
q Perform installation in the reverse order to re- 3 Damper assembly mounting bolt:
moval. 245 to 309 Nm {25 to 31.5 kgm}
a Use only ENS grease to charge the damper.
Using grease other than ENS will result in an
abnormal grease heat, earlier deterioration, or
earlier deterioration of seal materials.
Before charging the damper with ENS grease,
completely remove old grease from the damper.
Also, before using ENS grease, completely
discharge other grease remaining in the grease
gun to be used.
a For the procedure for charging the bearing
chamber with ENS grease, see "Disassembly
and assembly of damper assembly".
[*1]
3 Drive shaft mounting bolt:
157 to 196 Nm {16 to 20 kgm}
[*2]
q Use tool B5 to install the cover assembly.
2 Mounting face on cover:
3 Cover assembly mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
q Installing shaft (9)
1) Apply lubricant to spline part "e" of shaft (9),
and dry it (leave a few minutes after lubri-
cating) before installation.
2 Shaft spline part "e":
Molybdenum disulfide lubricant
(LM-P)
2) When installing shaft (9) to damper assembly
(10), apply grease to part "f".
100 g (ENS grease)
q ENS grease part No.: 427-12-11871 (2 kg
can)
50-90 WA1200-6
Disassembly and assembly of damper
Disassembly and assembly of damper 50-91
Special tools 50-91
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
1 SMT-890-1830 Spacer t 1 Q
2 SMT-890-1710 Sleeve t 1 Q
B 3 SMT-890-1810 Push tool t 1 Q
790-201-2100 Push tool t 1
4
790-201-2390 q Plate t 1
Disassembly 50-91
1. Damper cover
1) Remove cage (4). 7) Using tool [1], remove two bearings (10) and
2) Remove seal (2) from cage (4). spacer (11) from damper cover (1).
a Do not reuse the removed oil seal. a Do not reuse the removed bearing.
3) Using tool B4, remove spacer (21).
4) Remove snap ring (5).
5) Pull out cover (1) from shaft (3).
6) Remove oil seal (6), breather (7), elbow (8),
tube (9), and fitting (22) from damper cover
(1).
a Do not reuse the removed oil seal.
WA1200-6 50-91
2. Damper 3) Remove inner body (18) from outer body

1) Remove 20 mounting bolts (12), and remove (17).
flange (13) using forcing screws.
4) Reverse outer body (17), remove 20

mounting bolts (19), and remove flange (20)
using forcing screws.
2) Remove large rubbers (15) and small

rubbers (16).
5) Remove mounting bolts (21) from inner body

(18), and remove washers (22) and plate
(23).
50-92 WA1200-6
Assembly 50-93 1. Damper

1) Install plate (23) and washers (22) to inner
a Use only ENS grease to charge the damper. body (18), and tighten mounting bolt (21).
Using grease other than ENS will result in an 2 Contact surfaces on inner body
abnormal grease heat, earlier deterioration, or and plate:
earlier deterioration of seal materials. Liquid gasket (LG-8)
Before charging the damper with ENS grease, 3 Mounting bolt:
completely remove old grease from the damper. 98 to 123 Nm {10 to 12.5 kgm}
Also, before using ENS grease, completely
discharge other grease remaining in the grease
gun to be used.
2) Install flange (20) to outer body (17), and

tighten 20 mounting bolts (19).
2 Contact surfaces on outer body
and flange:
3 Mounting bolt
245 to 309 Nm {25 to 31.5 kgm}
WA1200-6 50-93
3) Reverse outer body (17), and install inner 5) Install flange (13), and tighten 20 mounting
body (18). bolts (12).
2 Contact surfaces on outer body
and flange:
3 Mounting bolt
245 to 309 Nm {25 to 31.5 kgm}
6) Install O-ring (23) in inner body (18).
4) Alternately insert 125-mm large rubbers (15)

and 100-mm small rubbers (16) between
inner body (18) and outer body (17).
2 Whole surface of rubber:
ENS grease
a After installing the rubbers, charge the
part P with ENS grease fully.
q ENS grease part No.: 427-12-11871 2. Damper cover
(2kg can) Bearing
a Install large and small rubbers as shown 1) Set tool B1 on the press bench, and then
in the figure, viewing from the flywheel place damper cover (1) on tool B1.
side. a Take care not to set the damper cover tilt-
a After installing the rubbers, check that ed.
mark "a" (at four portions on the periph-
ery) of the outer body matches the lever
end of the inner body.
50-94 WA1200-6
2) Apply adhesive on the periphery of bearing Cover

(10A), and press fit the bearing into the 1) Reverse cover (1), set oil seal (6) to the press
press-fit part of damper cover (1) using instal- fit part, and press fit the oil seal by using
lation tool B2. installation tool B3.
a Be careful to install shields (a) and (b) of 2 Outer periphery of oil seal: Adhe-
the bearing facing toward the seal.(See sive (LOCTITE 601)
the following figure.) a Degrease the inner periphery of cover (1)
a Apply grease to the open side (opposite and the outer periphery of oil seal (6).
of the shield side) of the bearing. a Take care that the oil seal does not slant.
2 Outside periphery of bearing: 2) Apply grease to clearance "S" between oil
Adhesive (LOCTITE 601) seal (6) and bearing (10A).
2 Open sides "X" and "Y" of bearing: a Also apply grease to the oil seal lip part.
ENS grease (150 g /bearing) 2 Clearance "S" between oil seal and
bearing:
ENS grease (70g)
q ENS grease part No.: 427-12-11871 (2
kg can)
3) Install spacer (11) aligning it with the inner

diameter of bearing (10A).
4) Press fit bearing (10B) following the same
procedure in Step 2.
a When press fitting the bearing, make sure 3) Install tool B2 at the bottom of bearing (10B),
that inner diameter of the spacer matches and clean and degrease the inner periph-
that of the bearing. eries of bearings (10A) and (10B) and the
a Press fit bearings one by one. outer periphery of shaft (3).
a After pressing fit the bearing, check that 4) Apply adhesive to the inner peripheries of
the clearance "a" is within the standard bearings (10A) and (10B).
value by using the feeler gauge. 2 Inner peripheries of bearings (10A)
q Standard clearance "a": 0.1 to 0.6 mm and (10B):
Adhesive (LOCTITE 601)
5) Install protector (14) to shaft (3).
6) Insert shaft (3) from the top of cover (1).
a Be careful not to cause an interference
between the lip of oil seal (6) and the
edge of the shaft.
7) Press fit shaft (3) while carefully turning cover
(1) so that the lip of oil seal (6) is not peeled.
WA1200-6 50-95
8) Reverse cover and shaft assembly (1), and 11)Press fit oil seal (2), and apply grease to
install snap ring (5). clearance "T".
a Securely install the snap ring in the a Also apply grease to the oil seal lip.
groove. 2 Clearance "T" between oil seal and
bearing:
ENS grease (100 g)
kg can)
9) Press fit spacer (21).

2 Inside surface of spacer: Adhesive
(LOCTITE 601)
a Check that level difference "b" between
the cover and bearing is within the stan- 12)Install cage (4) and oil seal (2) to cover (1).
dard value by using the gauge. 2 Mating faces U on cage (4) and cov-
q Standard value of level difference "b": er (1):
5.05 to 6.65 Liquid gasket (LG-8)
10)Press fit oil seal (2) to cage (4) using installa- 3 Bolt:
tion tool B4. 98 to 123 Nm {10 to 12.5 kgm}
2 Outer periphery of oil seal: Adhe-
sive (LOCTITE 601)
a Degrease the inner periphery of cage (4)
and the outer periphery of oil seal (2).
a Take care that the oil seal does not slant.
13)Install breathers (7) and (8), and plug (9).

3 Breather (7):
50-96 WA1200-6
4.9 to 9.8 Nm {0.5 to 1.0 kgm} 3. Charging bearing chamber with grease
3 Elbow (8): a Be sure to charge it with the specified amount
4.9 to 9.8 Nm {0.5 to 1.0 kgm} of grease.
3 Bolt (Tube mounting bolt): a Before charging the bearing chamber with
98 to 123 Nm {10 to 12.5 kgm} ENS grease, make sure that other greases
3 Fitting (22): are completely removed from it. Never mix
2.9 to 4.9 Nm {0.3 to 0.5 kgm} ENS grease with other greases. Use a
grease gun exclusive to the ENS grease.
1) Charge grease reservoir "d" between bear-
ings with the grease from fitting (22),
2 Bearing grease reservoir "d":
ENS grease (1860 ± 50 g)
q ENS grease part No.: 427-12-11871 (2 kg
can)
4. Damper and damper cover

1) Apply lubricant to spline part "e" of shaft (3),
and dry it (leave a few minutes after lubri-
cating) before installation.
2 Shaft spline part "e":
Molybdenum disulfide lubricant
(LM-P)
2) When installing shaft (3) to inner body (18),
charge part "f" with the grease.
ENS grease (100g)
kg can)
WA1200-6 50-97
Removal and installation of bumper and fuel tank assembly
Removal and installation of bumper and fuel tank assembly 50-98
Removal 50-98
k Before performing removal, be sure to imple- 8. Lift and remove steps (9) and (10).
tions during work" in "00 Safety notice". 9. Remove step covers (11), (12), (13), and (14).
1. Drain fuel from the tank. 10. Disconnect hoses (15) and (16).
6 Fuel:
Approx. 5,100 l(specified amount) 11. Disconnect fuel level sensor wiring harness
connector R05 (18).
2. Lift and remove handrail (1).
3. Lift and remove ladder (2).

4 Ladder:
170 kg
4. Lift and remove handrails (3) and (4).
5. Lift and remove step (5).
12. Disconnect wiring harness connector GR1 (19).
7. Remove step (8).
50-98 WA1200-6
Removal and installation of bumper and fuel tank assembly
13. Set a support stand [1] under the bumper. Installation 50-9
14. Sling the right and left sides of the bumper with q perform installation in the reverse order to the re-
nylon slings, remove mounting bolts (20), and moval.
then remove the bumper and fuel tank assembly
(21). [*1] [*1]
a To avoid damage to the nylon slings, use 3 Fuel tank mounting bolt:
cushioning material at bumper corners. 1,127 to 1,911 Nm {115 to 195 kgm}
4 Bumper and fuel tank assembly:
6,950 kg
15. Remove side fuel tanks (23), (24) and center fuel
tank (25) from bumper (22).
4 Side fuel tanks (23), (24):
500 kg (each)
Center fuel tank (25):
630 kg
a When removing the bumper and fuel tank,
make sure that all the wiring harnesses and
piping are disconnected.
WA1200-6 50-99
Removal and installation of hood assembly
Removal and installation of hood assembly 50-10
Removal 50-10 Installation 50-10

k Before performing removal, be sure to imple- q Perform installation in the reverse order to re-
ment "2. Preparatory work" in "00 Safety no- moval.
tice".
[*1]
1. Sling and remove handrail (1) and right and left Alignment procedure for installing exhaust pipe
handrails (2). q When installing the muffler stack, align the cen-
ters of the muffler stack and the muffler exhaust
2. Sling and remove two exhaust pipes (3). port according to the following procedure.
[*1] 1. Before installing the muffler stack, prepare a
4 Exhaust pipe: pattern [1] of the following dimensions.
30 kg x 2 pipes A (outside diameter): f392 mm
B (inside diameter): f162 mm
3. Remove right and left side covers (4).
4. Remove the mounting bolt, and sling and

remove hood assembly (5). [*2]
5. Sling and remove right and left brackets (6). [*3]
50-100 WA1200-6
Removal and installation of hood assembly
2. Fit the prepared pattern [1] to the muffler exhaust

port [2] aligning the its center hole with the center
of the muffler exhaust port, and put markings (C)
at four places along the periphery of the pattern
with a marker pen.
a After putting the markings, remove the pat-
tern.
3. Install the muffler stack aligning the flange

periphery with the markings.
a The displacement of the muffler stack hole
from the center must be less than 5 mm.
[*2]
3 Connecting nut of hood and radiator
guard:
490 to 608 Nm {50 to 62 kgm}
[*3]
3 Mounting nut of bracket (6):
490 to 608 Nm {50 to 62 kgm}
WA1200-6 50-101
Disassembly and assembly procedures for MESABI oil cooler
Disassembly and assembly procedures for MESABI oil cooler 50-102
q Outline
1. Name of each part of oil cooler assembly
50-102 WA1200-6
WA1200-6 50-103
2. Specifications and points

This is a very large assembly. The overall dimensions are approximately 2,162 mm (H) x 2,880 mm (W) x
143 mm (D), and the number of tubes is 912. The tubes are installed in the top and bottom cores, and
every four tubes are arranged in an array.
1) It is difficult to locate leakages with the oil cooler installed on the actual machine. Leakages can be
located only in the ribless area on the front side.
2) Tubes are installed in the top and bottom cores. Before removing tubes in the bottom cores, you have
to remove tubes in the top cores. (If you remove only the retainer clips in the top cores, the tubes in the
bottom cores are still connected firmly and cannot be removed.)
a To assemble, install the tubes to the bottom cores, and then install those in the top cores.
For these reasons, you may perform repair on the actual machine only when the problem is located on the
front side where replacement is easy. In other cases, transfer the assembly to the workshop and place it
level before starting repair work.
3. List of tools for disassembly and assembly

Sym-
Device Part No. Part name Q'ty Nature of work, remarks
bol
A 793-803-1110 Support instrument 1
Removal and installation of
B 793-803-1130 Tube instrument 1
core
Disassembly and C 793-803-1120 Breaker tool 1
assembly of oil cooler D 793-301-1600 Air leak checker 1
E 793-803-1150 Flange 1 Air leak check on the cores
F 793-803-1160 Flange 1
4. Spare parts list

No. Part No. Part name Q'ty Remarks
1 LM35780 Rubber seal 1,824
2 LM63377 Copper washer 2,736
3 LM33567 Tube retainer 912
4 LM33083-107 Air baffle 2
5 LM123-10-4200 ITS tube 912
6 LM48622 Tube support 912
Note: Blind plugs are not available as service parts because they cannot be used due to high operation pres-
sure.
50-104 WA1200-6
Disassembly and assembly of MESABI oil cooler
Disassembly and assembly of MESABI oil cooler 50-105
Preparation work 50-105 3) Place the oil cooler assembly on a level work
1) Clean the oil cooler assembly by using a hot stand.
water cleaner. Turn around the assembly a Place a corrugated or wooden board on
and clean the other side. the oil cooler so that you can place ob-
a Use a detergent. jects on it.
a Pressure: Max. 1,200 PSI, 8.3 MPa a If it is necessary for a worker to climb the
{84.4 kg/cm2} assembly during work, place a durable
a Water temperature: Max. 180 deg. F wooden plate on the assembly to protect
{82 °C} the tubes and fins against excessive
a Do not use steam. stress.
2) When cleaning is finished, remove excessive Disassembly 50-105

water by using an air blower. a To remove all tubes, first remove the two arrays
of tubes on the front, then turn around the oil
cooler assembly and remove the two arrays of
tubes on the rear.
1. Remove the support bar.

a Before removing the support bar, put a
matchmark to indicate its installed position.
WA1200-6 50-105
2. Removal of tubes 4) For easy tube removal, apply lubricating oil to

a First remove the tubes from the top cores. the top seal, bottom seal, and tube support.
1) Use pliers to pinch the tube, and then remove
the retainer clip.
5) The tube and rubber seal may stick together

to make the removal difficult. In this case,
2) Clean the tubes by using air, and wipe off the remove the tube while wobbling it by using
stain. breaker tool C.
3) Reposition the copper washer toward the fin 6) Remove the tube from the bottom seal by
(bottom side) so that it does not generate using tube instrument B.
resistance when removing the tube. a Set the tube instrument so that its round
part is parallel to the fin of the tube. Apply
the lower jaw to the plate on the center
tank and tighten the handle.
*1: The location to which the round part is
applied for the first time
(After the round part presses the fin to
cause the tube to come off a little)
50-106 WA1200-6
8) If the tube sticks firmly and does not move,

remove it by using tube instrument B and
support instrument A together.
a Stop pressing when the spigot joint por-
tion comes off. If you move it too much,
the tube support may interfere with the
fin, bending the fin.
7) Because the tube cannot be removed in the

first attempt, apply the round part of the tube
instrument to the side of the copper seal and
tighten the handle until the tube end comes
off.
*2: The location to which the round part is
applied for the second time
9) Remove the tube.
a While removing the tube from the top
seal, hold the tube in a horizontal position
to prevent the tube end from being dam-
aged or the tube from being kinked.
a After performing steps 6) and 7), check

that the tube support is disengaged.
WA1200-6 50-107
10)Under the original tube installation condition,

the tools cannot work well in the ribbed loca-
tions at the four corners of the oil cooler.
Change the tube fin direction 90 degrees by
using breaker tool C before starting the
removal procedure.
11)Pull and remove the rubber seal by using

thin-tipped pliers.
3. After disassembling the top two cores, turn over

the assembly and disassemble the bottom two
cores by using the same procedure.
50-108 WA1200-6
Assembly 50-109 a If you insert the rubber seal too much, the
rubber seal is deformed in a concave
a Clean the surface of each part and the inner sur- shape, reducing the inner diameter. The
face of holes, etc. by using a factory rag and air. reduced inner diameter generates exces-
1. Installation of tube sive stress when a tube is inserted, dam-
1) Install the rubber seal by hand. aging the seal. Install the rubber seal
a If the rubber seal is hard due to low tem- carefully.
peratures, warm it in hot water before in-
stallation.
a Never use lubricating oil because oil film
can cause oil leakage.
a Tap the rubber seal lightly by using a
flat-head hammer so that part (a) of the
rubber seal makes tight contact.
2) Apply a sufficient amount of oil to the tube

end and the inner surface of the rubber seal.
3) Also apply a sufficient amount of oil to the

tube support.
WA1200-6 50-109
4) Check that copper washers are placed at

both ends of the tube. 8) Insert the tube by hand until the meshing
q Top end: 2 pieces portion of the tube support comes to the tube.
q Bottom end: 1 piece a If you attempt to insert the tube by using
a When the assembly is installed on the a tool though the tube is not aligned with
machine and is in vertical position, place the hole in the rubber seal, the rubber
the copper washer at the bottom end im- seal is pressed, resulting in the same
mediately before inserting the tube into condition as that caused by excessive in-
the bottom seal to prevent the copper sertion where the rubber seal may be
washer from falling. damaged.
5) Align the top end of the tube with the hole in
the rubber seal, and then insert the tube.
9) Using tube instrument B and support instru-

ment A, insert the tube until the copper
6) Check the position of the tube support. washer contacts the end surface of the
rubber seal.
7) Align the bottom end of the tube with the hole

in the rubber seal, and then insert the tube a 10)Install the retainer clip between the copper
little by hand. washers by using pliers.
50-110 WA1200-6
a Adjust the retainer clip tab position to pre- 13)Because there are ribs in corner areas,
vent air leakage (for prevention of im- working in those areas is very difficult. Pay
paired cooling performance). sufficient attention when positioning and
a If you moved the air buffer to disassemble inserting the tube into the hole.
the assembly partially, be sure to return it a The work must be done by two people in
to the original position. a well-illuminated environment.
11)If the tube support is in a wrong position, the

support bar cannot be installed. Adjust the
tube support position by using breaker tool C.
14)In corner areas, install the tubes for four
arrays as a bundle.
a When you finish installing the tubes to the
bottom cores, install the tubes to the top
cores.
12)If the tube is bent, correct it by using breaker

tool C.
WA1200-6 50-111
2. Install the support bar. 3. Apply and hold air pressure.

After installing tubes on the front side, install the a Air pressure: 0.88 to 1.03 MPa {9.0 to
support bar by using the matchmark that you put 10.5 kg/cm2}
in the disassembly procedure. a Check the jig for air leakage by using soap
water.
3. Turn over the oil cooler by using a lifting hook.

Install the two arrays on the other side. 4. Disconnect the air source pressure hose.
5. Check that the air pressure does not decrease in
Pressurization test 50-1 2 one hour.
1. Install flange E to the outlet port of the oil cooler. a If a decrease in air pressure is found, locate
the air leakage audibly or by using soap wa-
ter or a bath containing clean water.
2. Install flange F to the inlet port of the oil cooler,

and then install air leak checker D.
50-112 WA1200-6
Power train
Removal and installation of torque converter and transmission assembly
Power train 50-1 3

Removal and installation of torque converter and transmission
assembly 50-1 3
Removal 50-1 3 8. Lift and remove drive shaft guards (3) and (4).
ment "2. Preparatory work", "3. Precautions 9. Lift and remove underguards (5) and (6).
during work", and "8. Precautions for discon-
necting and connecting hoses and tubes in
an air conditioner circuit" in "00 Safety no-
tice".
k Collect the refrigerant (air conditioner gas:
R134a) from the air conditioner circuit.
1. Drain the hydraulic oil.

6 Hydraulic oil:
approx. 1,125 l
2. Drain the transmission oil.

6 Transmission oil:
approx. 350 l
10. Disconnect wiring harness connectors R31(7a)
and R32(7b).
"Removal and installation of hood assembly".
4. Remove the bulkhead assembly, referring to

"Removal and installation of bulkhead
assembly".
5. Remove the operator’s cab assembly. For

details, see "Removal and installation of oper-
ator’s cab assembly".
6. Lift and remove the floor cover from the top of

the transmission.
7. Remove steps (1) and (2).
11. Disconnect air conditioner hose (8). [*1]
12. Remove air conditioner condenser assembly (9)

together with the bracket.
WA1200-6 50-113
Power train
13. Disconnect hoses (10), (11), (12), (13), and (14). 17. Disconnect hoses (21), (22), (23), (24), and (25).
18. Disconnect pump outlet hoses (26), (27), and

(28).
19. Disconnect suction tubes (29) and (30).
14. Remove U-bolt (16).

50-114 WA1200-6
Power train
21. Remove hose clamps (33) and disconnect nine 27. Disconnect hoses (50), (51), (52), and then lift
hoses (34). and remove lower emergency steering pump
assembly (53).
a In the same way as the above procedure, re-
move the upper emergency steering pump
assembly.
22. Remove hose clamp (35) and disconnect hoses

(36) and (37).

28. Disconnect hoses (101), (102), (103), and (104).
24. Disconnect wiring harness connector MT3 (41).

29. Disconnect tubes (105), (106), (107), and (108).
26. Remove valve assembly (46). [*2]
WA1200-6 50-115
Power train
30. Disconnect hoses (54) and (55) and remove 36. Remove hoses (67) and (68).
transmission oil filler (56).
37. Disconnect tubes (69), (70), (71), and (72).
38. Remove clamp (73) and remove hose (74).
40. Remove suction tube (76).
31. Disconnect hoses (57), (58), and (59).
42. Remove hoes and remove suction tubes (95)

and (96).
32. Disconnect six hoses (60).
33. Remove hose clamp (61) and disconnect hose

(62).
34. Remove hose clamp (63) and disconnect hoses

(64) and (65).
50-116 WA1200-6
Power train
44. Remove the wiring harness clamps and discon- 47. Sling upper drive shaft (83), remove mounting
nect wiring harness connectors TM1 (78) and bolts, and then remove the upper drive shaft.
TM2 (79). [*3]
a Remove the drive shaft after putting match
marks on the coupling to indicate the mount-
ing position.
4 Upper drive shaft:
115 kg
48. Sling rear drive shaft (84), remove mounting

bolts, and then remove the rear drive shaft. [*4]
ing position.
4 Rear drive shaft:
290 kg
45. Disconnect hose (80). 49. Sling center drive shaft (85), remove the
mounting bolts, and then remove the center
drive shaft. [*5]
ing position.
4 Center drive shaft:
190 kg
50. Sling transmission assembly (86) and remove

the rear mount mounting bolts (87). [*6]
51. Remove mounting bolts (89) and (90), and

remove right and left front mount brackets (88).
[*7]
WA1200-6 50-117
Power train
52. Slowly lift and remove transmission assembly

(86).
a When removing the transmission assembly,
make sure that all the piping and wiring har-
nesses are disconnected.
4 Transmission assembly:
6,550 kg
a When lifting the transmission assembly, use
wire ropes longer than 2.0 m on the transmis-
sion (a).Adjust the length of the wire ropes on
the torque converter (b) to lift the transmis-
sion in a horizontal attitude.
50-118 WA1200-6
Power train
Installation 50-1 9
q perform installation in the reverse order to the removal.
[*1]
2 O-ring (on hose connection):
Apply compressor oil (ND-OIL8) for the new refrigerant.
a Fix the nut securely by using two wrenches.
(Hold the device side to prevent it from moving and turn only the flare nut of the hose with the wrench.)
3 Piping connections
Tightening torque
Connection Hose size/ Tube size Thread size Used at
Nm {kgm}
COND1 out
118 to 147
f8 M16 x 1.5 COND2 out
{12 to 15}
rec to unit in
Nut type 196 to 245 COND1 in
D 1/2 M22 x 1.5
{20 to 25} COND2 in
294 to 343
D 5/8 M24 x 1.5 Unit out
{30 to 35}
Receiver tank 39 to 69
Receiver tank
M16 x 1.5 {4.0 to 7.0}
Block joint
Other than receiver 78 to 118
Compressor A/C unit
tank M16x1.5 {8.0 to 12}
q Filling of refrigerant (air conditioner gas: [*7]

R134a) 3 Front mount bracket mounting bolt:
Fill the air conditioner circuit with the refrigerant q Bolt (89): 785 to 980 Nm {80.0 to 100 kgm}
(R134a). q Bolt (90): 785 to 980 Nm {80.0 to 100 kgm}
a Filling quantity: 1,400 ± 100 g
a If gas leakage occurs after tightening the flare q Refilling with oil (transmission)
nut, clean the flare portion, apply ND-OIL8, and Add oil through the oil filler port to the specified
then tighten it to the specified torque shown in level. Run the engine to circulate the oil through
the above table. the system. Then, check the oil level again.
[*2] q Refilling with oil (hydraulic tank)

3 Valve assembly mounting bolt: Refill the hydraulic tank with oil through the oil
44.1 to 53.9 Nm {4.5 to 5.5 kgm} filler port to the specified level. Run the engine to
circulate the oil through the system. Then, check
[*3] the oil level again.
3 Upper drive shaft mounting bolt:
157 to 196 Nm {16 to 20 kgm} q Precautions for filling air conditioner with re-
frigerant
[*4] See "8. Precautions for connecting hoses and
3 Rear drive shaft mounting bolt: tubes, and filling of refrigerant in the air condi-
343 to 427 Nm {35 to 43.5 kgm} tioner circuit" in "00 Safety notice".
[*5] q Air bleeding

3 Center drive shaft mounting bolt: Bleed air from the piston pump and work equip-
343 to 427 Nm {35 to 43.5 kgm} ment hydraulic circuit. For details, see "Bleeding
air from piston pump" and "Bleeding air from
[*6] work equipment circuit and steering circuit".
3 Rear mount mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
WA1200-6 50-119
Power train
Disconnection and connection of transmission assembly and torque converter assembly
Disconnection and connection of transmission assembly and torque

converter assembly 50-120
50-120 WA1200-6
Power train
Replacing consumables 50-121
a Replace all consumable parts (O-rings, seal 5. Disconnecting torque converter assembly
rings, etc.) used with new ones when re-con- 1) Sling torque converter assembly (9), and
necting the transmission and torque converter remove 25 mounting bolts.
assemblies. 2) Disconnect torque converter assembly (9)
from transmission assembly (10).
List of consumables to be replaced at service a Horizontally pull out the torque converter
KIT No.: 42C-15-05060, 42C-15-05270 until the input shaft of the transmission is
For details of KIT No., see the end of this section. separated completely.
4 Torque converter assembly:
Disconnection 50-121 Approx. 1,500 kg
1. Preparation work 4 Transmission assembly:
Support the torque converter assembly with Approx. 3,800 kg
blocks, etc. so that it is kept level. a For procedures for disassembling the
k Securely hold the bottom of the transmis- torque converter assembly, see "Disas-
sion case so that the transmission assembly and assembly of torque convert-
sembly does not fall down when the er".
torque converter assembly is disconnect- a For procedures for disassembling the
ed. transmission, see "Disassembly and as-
sembly of transmission".
2. Wiring harness
Remove wiring harness (1).
a Also remove wiring clamp.
3. Tube
1) Remove clamp and two mounting bolts to
remove bracket (2).
2) Remove six mounting bolts to remove drain
tube (3).
tube (4).
tube (5).
5) Remove eight mounting bolts to remove
lubrication tube (7).
6) Remove two mounting bolts to remove lubri-
cation tube (6a).
4. Lubrication hose
Removes lubrication tubes 6a and 6b.
a Remove hose clamp as well.
WA1200-6 50-121
Power train
Connection 50-12
1. Preparation work
Support the transmission assembly with blocks,
etc. so that it is kept level.
2. Connecting torque converter assembly

1) Fit the O-rings to the joint portion of torque
converter assembly (9) and transmission
assembly (10).
2 O-ring:
Grease (G2-LI)
2) Sling torque converter assembly (9), and
install it to transmission assembly (10) with
25 bolts.
4 Torque converter assembly:
Approx. 1,500 kg
4 Transmission assembly:
Approx. 3,800 kg
3. Lubrication hose
Install tubes (6a) and (6b).
a Secure them with the hose clamps.
4. Tube
1) Fit the O-ring, and install lubrication tube (6a)
by using two bolts.
2) Fit the O-ring, and install lubrication tube (7)
by using eight bolts.
3) Fit the O-ring, and install drain tube (5) by
using six bolts.
using six bolts.
using six bolts.
6) Install bracket (2) by using two bolts and
clamps.
5. Wiring harness
Install wiring harness (1).
a Fix with a wiring clamp.
50-122 WA1200-6
Power train
Service kit parts list Service kit parts list

KIT No.: 42C-15-05060 (Torque converter and KIT No.: 42C-15-05270 (Torque converter and
transmission connection service kit) transmission connection service kit)
Fig.No.: Y0 Y99-0000002 (K05) (Transmission Fig.No.: Y0 Y99-0000002 (K04) (Transmission
case) case)
Index Part No. Part name Q'ty Index Part No. Part name Q'ty
7 19M-15-11440 O-RING 1 22 07000-73032 O-RING 7
8 07000-72125 O-RING 2 23 07000-73050 O-RING 10
9 07000-73040 O-RING 1 24 07000-73040 O-RING 4
10 07000-73048 O-RING 1 26 07000-73025 O-RING 1
11 07000-72075 O-RING 1
12 07000-72065 O-RING 1
21 07000-72125 O-RING 2
WA1200-6 50-123
Power train

Fig.No.: Y0 Y99-0000002 (K04) (Transmission pip- Fig.No.: Y0 Y99-0000002 (K04) (Transmission
ing) valve seat)
3 07005-02012 GASFET 4 6 07000-72018 O-RING 6
9 07005-02012 GASFET 4 7 07000-72021 O-RING 7
12 07005-02012 GASFET 4 8 07000-73032 O-RING 2
15 07005-02012 GASFET 6 9 07000-73050 O-RING 1
18 07005-02012 GASFET 4
22 07000-73048 O-RING 1
40 07000-73050 O-RING 1
50-124 WA1200-6
Power train

Fig.No.: Y0 Y99-0000002 (K04) (Transmission con- Fig.No.: Y0 Y99-0000002 (K04) (Transmission
trol valve filter) flange cover)
7 07000-73028 O-RING 2 25 02896-61015 O-RING 1
9 07000-73022 O-RING 2 27 07002-62034 O-RING 2
15 07000-73035 O-RING 3
WA1200-6 50-125
Power train

Fig.No.: Y0 Y99-0000002 (K04) (Transmission wir- Fig.No.: Y0 Y99-0000002 (K04) (Transmission wir-
ing and piping) ing and piping)
9 07000-72105 O-RING 3 4 07000-73025 O-RING 1
10 07000-72090 O-RING 3 6 07002-62034 O-RING 1
7 02896-61015 O-RING 1
14 07000-73025 O-RING 1
22 07000-73048 O-RING 2
50-126 WA1200-6
Power train
Disconnection and connection of torque converter assembly, PTO and transfer assembly
Disconnection and connection of torque converter assembly, PTO and

transfer assembly 50-127
WA1200-6 50-127
Power train
Disconnection 50-128 5. Modulation clutch ECMV assembly

1) Remove three mounting bolts to remove
1. Breather and breather hose cover (24).
1) Remove breather hose (1). 2) Remove four mounting bolts, and remove
2) Remove two mounting bolts, and remove modulation clutch ECMV assembly (25).
breather (2) and the block as a unit.
3) Remove elbow (3). 6. Speed sensor
Loosen the locknut and remove speed sensor
2. Lubrication tube and block (26).
1) Remove lubrication tubes (21) and (22).
a Remove the tube clamps also. 7. Modulation clutch assembly
2) Remove four mounting bolts and flange, and Remove ten mounting bolts, and remove modu-
remove lubrication tube (6). lation clutch assembly (27).
a Remove the tube clamp also. a The hexagonal socket bolt is not a mounting
3) Remove four mounting bolts to remove block bolt. Do not remove it.
(7). a Using forcing screws (12 mm), pull out the
4) Remove lubrication tube (8). assembly.
5) Remove three joints and remove lubrication a Since the inner and outer races of the roller
tube (9). bearing are separated, pull it out horizontally
6) Remove two joints from each lubrication so that it is not pried.
tube, and remove lubrication tubes (10), (11), 4 Modulation clutch assembly:
(12) and (13). 220 kg
7) Remove two mounting bolts, and remove a For procedures for disassembling the modu-
block (14) and bracket (15). lation clutch, see "Disassembly and assem-
8) Remove three mounting bolts to remove bly of modulation clutch".
block (16).
8. Torque converter assembly, and PTO and
3. Main relief valve and torque converter relief transfer assembly
valve assembly 1) Remove 19 mounting bolts, and disconnect
Remove seven mounting bolts, and remove torque converter assembly (28) from PTO
main relief valve and torque converter relief and transfer assembly (29).
valve assembly (17). 4 Torque converter assembly:
430 kg
4. Torque converter regulator valve assembly 4 PTO and transfer assembly:
1) Remove four mounting bolts to remove block 800 kg
(18). a For procedures for disassembling the
2) Remove sleeve (19). torque converter, see "Disassembly and
3) Remove four mounting bolts, and remove assembly of torque converter".
cover (20) and block (21). a For procedures for disassembling the
4) Remove four mounting bolts, and remove PTO and transfer, see "Disassembly and
torque converter regulator valve assembly assembly of PTO and transfer".
(22). 2) Remove coupling (30) from torque converter
5) Remove valve block assembly (23). assembly (28).
50-128 WA1200-6
Power train
Connection 50-129 4. Modulation clutch ECMV assembly

1) Fit the O-ring and install modulation clutch
1. Torque converter assembly, and PTO and ECMV assembly (25) with four bolts.
transfer assembly 3 Mounting bolt:
1) Install coupling (30) to torque converter 27.4 to 34.3 Nm {2.8 to 3.5 kgm}
assembly (28). 2) Install cover (24) with three bolts.
2) Fit the O-rings to the joint portion of torque
converter assembly (28) and PTO and 5. Torque converter regulator valve assembly
transfer assembly (29). 1) Fit the O-ring and install valve block
2 O-ring: assembly (23) with four bolts.
Grease (G2-LI) 3 Mounting bolt:
3) Install torque converter assembly (28) to 44.1 to 53.9 Nm {4.5 to 5.5 kgm}
PTO and transfer assembly (29) with 19 2) Fit the O-ring and install torque converter
bolts. regulator valve assembly (22) with four bolts.
a Since the inner and outer races of the ta- 3 Mounting bolt:
per roller bearing are combined together, 44.1 to 53.9 Nm {4.5 to 5.5 kgm}
drop transmission oil (TO30 or TO10) 3) Fit the O-ring and install block (21) and cover
about 6 cc to the roller sliding surface. (20) with four bolts.
4 Torque converter assembly: 4) Fit the O-ring and install sleeve (19).
430 kg 2 O-ring:
4 PTO and transfer assembly: Grease (G2-LI)
800 kg 5) Fit the O-ring and install block (18) with four
bolts.
2. Modulation clutch assembly
Fit the O-ring and install modulation clutch 6. Main relief valve and torque converter relief
assembly (27) with ten bolts. valve assembly
2 O-ring: Fit the gasket and install main relief valve and
Grease (G2-LI) torque converter relief valve assembly (17) with
a Since the inner and outer races of the roller nine bolts.
bearing are combined together, drop trans- 3 Mounting bolt:
mission oil (TO30 or TO10) about 6 cc to the 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
roller sliding surface, and insert it horizontally
so that it is not pried. 7. Lubrication tube and block
4 Modulation clutch assembly: 1) Fit the O-ring and install block (16) with three
220 kg bolts.
2) Install bracket (15) and block (14) with two
3. Speed sensor bolts.
Install speed sensor (26) and secure it with the
lock nut.
2 Threaded portion of sensor:
a Apply the speed sensor end lightly to the
gear tooth tip located inside of the modula-
tion clutch, return the sensor from that posi-
tion by 1/2 to one turn, and secure the sensor
with the lock nut.
3 Locknut:
49.0 to 68.6 Nm {5 to 7 kgm}
WA1200-6 50-129
Power train
3) Fit the gasket and install lubrication tubes

(13), (12), (11) and (10) with two joints each.
3 Joint:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
4) Fit the gasket and install lubrication tube (9)
with three joints.
3 Joint:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
8. Lubrication hose and block

1) Install lubrication hose (8).
a Secure it with the hose clamp.
2) Install block (7) with four bolts.
3) Fit the O-ring and install lubrication hose (6)
with four bolts and flange.
4) Install lubrication hoses (5) and (4).
a Secure them with the hose clamps.
9. Breather and breather hose

1) Install elbow (3).
2) Install breather (2) with two bolts.
3) Install breather hose (1).
a Secure it with the hose clamp.
50-130 WA1200-6
Power train
Disassembly and assembly of torque converter
Disassembly and assembly of torque converter 50-131
WA1200-6 50-131
Power train
a Replace all consumable parts (O-rings, seal 4) Remove turbine (9).

rings, etc.) used in the torque converter and a Use forcing screws (10 mm) to pull out.
modulation clutch with new ones when re-as- 5) Remove ball bearing (10) from case (11).
sembling the torque converter and modulation a Since the bearing has a snap ring, take
clutch. care not to push the bearing from the
a For details of KIT No., see the end of this sec- snap ring side when removing the bearing
tion. with a press.
KIT No.: 42C-13-05280 and 42C-13-05290
5. Stator
Disassembly 50-132 1) Remove snap ring (12), then remove stator
1. Preparation work (13).
1) Set the torque converter assembly vertically 2) Remove spacer (14).
with the input shaft up.
a Adjust the height of the assembly using 6. Pump assembly
blocks to allow removal of the mounting 1) Remove pump assembly (15).
bolts from under the case. a Since the inner and outer races of the roll-
er bearing are separated, lift the assem-
2. Case bly straight up, taking care not to pry the
Remove 13 mounting bolts to remove the torque races.
converter from case (1). 2) Remove 16 mounting bolts to remove
a Attach the eyebolt (12 mm) to the end of the retainer (16) and guide (17) from pump (18).
input shaft, lift the torque converter vertically 3) Remove the outer race of roller bearing (19)
with all parts in the case assembled. from guide (17).
a Place the removed torque converter on a a Use a press to pull out.
work stand with the input shaft up. 4) Remove drain plug (20) from pump (18).
3. Input shaft 7. Shaft

1) Remove 20 mounting bolts to remove shaft 1) Remove four mounting bolts to remove plate
(2). (21) from shaft (22).
2) Remove the inner race of taper roller bearing 2) Remove seal ring (23) from shaft (22).
(3) from shaft (2). 3) Remove the inner race of roller bearing (19)
a Use a bearing puller to pull out. from shaft (22).
a Use a bearing puller to pull out.
4. Case and turbine assembly 4) Remove sleeve (24) from shaft (22).
1) Remove 36 mounting bolts to remove case
and turbine assembly (4).
2) Remove snap ring (5) to remove wire (6).
3) Remove snap ring (7) to remove cover (8).
50-132 WA1200-6
Power train
Assembly 50-13 2 Mounting bolt threaded section:

1. Shaft Adhesive (LT-2)
1) Install sleeve (24) to shaft (22). 3 Mounting bolt:
a Install the sleeve by expansion fit. 59 to 74 Nm {6.0 to 7.5 kgm}
2) Press fit the inner race of roller bearing (19) 4) Install pump assembly (15) to shaft (22).
to shaft (22). a Since the inner and outer races of the roll-
a Using a press, press fit the bearing until er bearing are combined together, lower
the end face of inner race comes in con- the assembly straight down, taking care
tact with the stepped part of the shaft. not to pry the races.
3) Install plate (21) to shaft (22) with four bolts.
4) Install seal ring (23) to shaft (22). 3. Stator
2 Seal ring: 1) Install spacer (14).
Grease (G2-LI) 2) Install stator (13) and secure it with snap ring
(12).
2. Pump assembly
1) Install drain plug (20) to pump (18). 4. Case and turbine assembly
3 Drain plug: 1) Install ball bearing (10) to case (11).
9.8 to 12.7 Nm {1.0 to 1.3 kgm} a Using a press, press fit the bearing until
2) Press fit the outer race of roller bearing (19) the snap ring comes in contact with the
into guide (17). stepped part of the case.
a Apply bearing compound to four places a After press fitting the bearing, drop trans-
on the bearing outer periphery. Wipe off mission oil (T030 or T010) about 6 cc to
any extra compound to prevent it from en- the sliding portion and rotate the bearing
tering into the bearing. ten turns to run in the bearing.
2) Install turbine (9).
a Holding the inner race of the ball bearing,
press fit the turbine until the stepped part
of the turbine comes in contact with the
end face of the inner race using a press.
3) Install cover (8) and secure it with snap ring
(7).
4) Install wire (6) and secure it with snap ring
(5).
5) Install case and turbine assembly (4) with 36
bolts.
a Align the oil groove in the inner periphery
of the case with the drain plug of the
pump.
2 Mounting bolt threaded section:
a Using a press, press fit the bearing until
Adhesive (LT-2)
3 Mounting bolt:
the end face of outer race comes in con-
tact with the stepped part of the guide.
49 to 59 Nm {5 to 6 kgm}
3) Install guide (17) and retainer (16) to pump
(18) with 16 bolts.
WA1200-6 50-133
Power train
5. Input shaft
1) Install the inner race of taper roller bearing
(3) to shaft (2).
the end face of inner race comes in con-
tact with the stepped part of the shaft.
2) Install shaft (2) with 20 bolts.
Adhesive (LT-2)
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
6. Case
Install the torque converter to case (1) with 13
bolts.
a Attach an eyebolt (12 mm) to the end of the
input shaft, lift the torque converter vertically
and install it.
Adhesive (LT-2)
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
50-134 WA1200-6
Power train

KIT No.: 42C-13-05280 (torque converter installa- KIT No.: 42C-13-05280 (torque converter installa-
tion service kit) tion service kit)
Fig. No.: Y0 Y99-0000002 (K01) (modulating clutch) Fig. No.: Y0 Y99-0000002 (K01) (modulating clutch)
(case) (clutch)
6 07000-72115 O-RING 1 5 124-960-2180 RING 2
7 07000-72018 O-RING 4 9 714-10-19220 RING SEAL 1
9 07002-61423 O-RING 3
10 07000-75160 O-RING 1
16 07000-75375 O-RING 1
17 07000-72115 O-RING 1
18 07000-75355 O-RING 1
23 07002-61423 O-RING 2
WA1200-6 50-135
Power train

Fig. No.: Y0 Y99-0000002 (K01) (modulating clutch) Fig. No.: Y0 Y99-0000002 (K01) (torque converter
(ECMV) input transfer case)
2* 561-15-55630 SHIM 3 4 42C-13-15280 GASKET 1
5* 07000-73025 O-RING 1
5* 07000-73028 O-RING 1
5* 07000-73035 O-RING 1
5* 07000-72018 O-RING 1
5* 07002-61023 O-RING 1
50-136 WA1200-6
Power train

Fig. No.: Y0 Y99-0000002 (K01) (torque converter Fig. No.: Y0 Y99-0000002 (K01) (torque converter
input transfer gear) input transfer gear)
6 42C-13-05010 SHIM KIT 1 4 42C-13-05030 SHIM KIT 1
7 07000-75385 O-RING 2 5 07000-75210 O-RING 1
16 42C-13-05020 SHIM KIT 1 12 42C-13-05040 SHIM KIT 1
19 07000-75425 O-RING 1 15 07000-72130 O-RING 1
20 07000-75200 O-RING 1
21 07000-75085 O-RING 1
22 07012-50110 SEAL OIL 1
29 07000-75270 O-RING 3
30 07000-75230 O-RING 1
WA1200-6 50-137
Power train

input transfer piping) input transfer piping)
12 07000-73028 O-RING 1 9 07002-62034 O-RING 2
18 07005-02012 GASKET 22 10 02896-61012 O-RING 2
24 07002-62434 O-RING 2 20 02896-61018 O-RING 2
25 02896-61015 O-RING 2
28 07002-62434 O-RING 2
29 02896-61015 O-RING 2
50-138 WA1200-6
Power train

input case) valve)
2 07000-72115 O-RING 1 9 07000-73038 O-RING 2
5 19M-13-13340 O-RING 1 13 07000-73042 O-RING 1
27 42C-13-22710 SEAL RING 1 17 07000-73048 O-RING 2
18 07000-72014 O-RING 4
26 42C-13-13110 GASKET 1
28 07000-73048 O-RING 1
34 07000-72018 O-RING 2
WA1200-6 50-139
Power train

valve) valve)
3 07000-73045 O-RING 2 7 07000-73045 O-RING 2
6 07000-72055 O-RING 3 12 07000-72014 O-RING 1
12 07000-72014 O-RING 1 13 07002-61023 O-RING 1
15 07002-61023 O-RING 1
50-140 WA1200-6
Power train
Service kit parts list

KIT No.: 42C-13-05290 (torque converter installa-
tion service kit)
Fig. No.: Y0 Y99-0000002 (K02) (torque converter
valve)
Index Part No. Part name Q'ty
3 07002-61023 O-RING 2
4 07000-72055 O-RING 2
18 07000-73045 O-RING 2
24 6206-21-9460 SHIM 6
25 42C-13-16220 SHIM 4
WA1200-6 50-141
Power train
Disassembly and assembly of modulation clutch
Disassembly and assembly of modulation clutch 50-142
50-142 WA1200-6
Power train
Special tools 50-143 5. Piston

1) Using tool C4, remove nut (24).
New/redesign
a For tool C4, see the "Sketches of special
Necessity
Sketch
Sym-
Q'ty
Part No. Part name tools".
bol
2) Remove plate (25).
3) Remove seal ring (26) from plate (25).
2 SMT-890-1230 Socket t 1 Q 4) Remove piston (27).
C
4 SMT-890-1310 Wrench t 1 Q a Push out the piston from the shaft side us-
ing forcing screw (12 mm).
Disassembly 50-143
1. Cage 6. Output drum
1) Remove four mounting bolts to remove cage Remove 12 mounting bolts to remove drum (28).
(1). a Push out the drum from the shaft side using
a Using forcing screws (12 mm), pull out the forcing screw (12 mm).
cage.
2) Remove snap ring (2), then remove bushing 7. Shaft
(3) and ball (4) from cage (1). 1) Remove seal rings (29) and (30) from shaft
(31).
2. Case 2) Remove two seal rings (32) from shaft (31).
1) Remove snap ring (5). 3) Remove the inner race of roller bearing (33)
2) Remove two mounting bolts to remove case from shaft (31).
(6). a Use a bearing puller to pull out.
3) Remove ball bearing (7) from case (6).
a Use a press to pull out.
3. Cover and input drum assembly

1) Remove cover and input drum assembly
(34).
2) Remove snap ring (8), then remove plate (9)
and ball (10).
3) Remove snap ring (11), then remove cover
(12) and ball (13).
4) Remove input drum (17) from cover (14).
5) Remove snap ring (15), then remove ball
bearing (16).
4. Discs and plates

1) Remove snap ring (18), then remove plate
(19).
2) Remove damper (20).
3) Remove 19 discs (21) and 18 plates (22)
alternately.
4) Remove damper (23).
WA1200-6 50-143
Power train
Assembly 50-14 3. Piston

1. Shaft 1) Install piston (27).
1) Press fit the inner race of roller bearing (33) 2) Install seal ring (26) to plate (25).
to shaft (31). 2 Seal ring:
a Using a press, press fit the bearing until Grease (G2-LI)
the end face of inner race comes in con- a Install the seal ring as shown in the draw-
tact with the stepped part of the shaft. ing below, paying attention to the installed
2) Install seal ring (32) to shaft (31). direction of the seal ring.
2 Seal ring:
Grease (G2-LI)
3) Install seal rings (30) and (29) to the shaft
(31).
2 Seal ring:
Grease (G2-LI)
a The seal ring has its installed direction.
Install the seal ring as shown in the draw-
ing below.
3) Install plate (25).

4) Using tool C4, install nut (24).
a For tool C4, see the "Sketches of special
tools".
2 Nut thread:
Adhesive (LT-2)
a Install the nut with its chamfered face facing
plate (25).
3 Sleeve nut:
2. Output drum 313.8 to 392.3 Nm {32 to 40 kgm}
Install drum (28) with 12 bolts.
2 Mounting bolt threaded portion: 4. Discs and plates
Adhesive (LT-2) 1) Install damper (23)
3 Mounting bolt: a Install the damper with its cork side facing
98 to 123 Nm {10.0 to 12.5 kgm} the piston.
2) Install 19 discs (21) and 18 plates (22) alter-
nately.
a Dip the discs in clean transmission oil
(T030 or T010) for at least two minutes
before installing.
3) Install damper (20)
a Install the damper with its cork side facing
plate (19).
4) Install plate (19), and secure it with snap ring
(18).
50-144 WA1200-6
Power train
5. Cover and input drum assembly 2) Install the O-ring to the cover side of case (6),
1) Using tool C2, install ball bearing (16) to install case (6) to shaft (31), and secure it
cover (14) and secure it with snap ring (15). with two bolts.
a Press fit the bearing until the end face of 2 O-ring:
the outer lace comes in contact with the Grease (G2-LI)
stepped part of the cover. a Using a press, push the inner race of ball
a After press fitting the bearing, drop trans- bearing (7) to press fit the bearing until
mission oil (T030 or T010) about 6 cc to the end face of inner race comes in con-
the sliding portion and rotate the bearing tact with the stepped part of the shaft.
ten turns to run in the bearing. a Check that the bearing has been press fit
in position before tightening two bolts.
3) Install snap ring (5).
7. Cage
1) Install ball (4) and bushing (3) to cage (1) and
secure the bushing with snap ring (2).
a Put the ball into the ball hole in the bush-
ing and install the bushing aligning the
ball with the ball groove in the cage.
2) Fit the O-ring and install cage (1) with four
bolts.
2 O-ring:
Grease (G2-LI)
2) Install input drum (17) to cover (14).

3) Install ball (13) and cover (12) and secure the
cover with snap ring (11).
a Put the ball into the ball hole in the drum
and install the cover aligning its ball
groove with the ball.
4) Install ball (10) and plate (9) and secure the
plate with snap ring (8).
a Put the ball into the ball hole in the cover
and install the plate aligning its ball
groove with the ball.
5) Install cover and input drum assembly (34).
6. Case
1) Install ball bearing (7) to case (6).
the end face of outer race comes in con-
tact with the stepped part of the case.
a After press fitting the bearing, drop trans-
mission oil (T030 or T010) about 6 cc to
the sliding portion and rotate the bearing
ten turns to run in the bearing.
WA1200-6 50-145
Power train
Disassembly and assembly of PTO and transfer
Disassembly and assembly of PTO and transfer 50-146
50-146 WA1200-6
Power train
WA1200-6 50-147
Power train
Special tools 50-148 a If no stamping mark of "UP" is found in the

cage, stamp mark "UP" on the side of the
New/redesign
Necessity
gauge cast hole to prevent wrong installa-
Sketch
Sym-
Q'ty
Part No. Part name tion.
bol
Assembly Draw-
SMT-890-1200 t 1 Q
ing
SMT-890-1240 Test/J t 1 Q
3
SMT-890-1250 Test/J t 1 Q
C Assembly Draw-
SMT-890-5600 t 1 N Q
ing
SMT-890-5610 q Gear t 1 N Q
5 SMT-890-5620 q Shaft t 1 N Q
SMT-890-5630 q Carburetor t 1 N Q
SMT-890-5640 q Plate t 1 N Q
6 SMT-890-5710 Test Jig t 1 N Q 2) Remove the outer race of taper roller bearing
(13) from cage (11).
Disassembly 50-148
3) Remove gear (14).
1. Speed sensor
4) Remove the inner races of taper roller bear-
Loosen the locknut and remove speed sensor
ings (13) and (15) from gear (14).
(1).
2. Cover
5. PTO gear 3 (gear B)
Remove 12 mounting bolts to remove cover (2).
cage (16) and shim (17).
3. PTO gear 1 (gear D)
a Note the number and thickness of the
1) Remove six mounting bolts to remove cage
shims for installation purpose.
(3) and shim (4).
a If no stamping mark of "UP" is found in the
gauge, stamp mark "UP" on the side of
the gauge cast hole to prevent wrong in-
2) Remove the outer race of taper roller bearing
stallation.
(5) from cage (3).
3) Remove coupling (6).
4) Remove snap ring (7) from coupling (6).
5) Remove gear (8).
6) Remove snap ring (9) from gear (8).
4. PTO gear 2 (gear C)

cage (11) and shim (12).
50-148 WA1200-6
Power train
2) Remove the outer race of taper roller bearing 9) Remove eight mounting bolts to remove
(18) from cage (16). cage (37) and shim (38).
a Use a press to pull out. a Note the number and thickness of the
3) Remove gear (19). shims for installation purpose.
4) Remove the inner races of taper roller bear- 10)Remove the outer race of taper roller bearing
ings (18) and (20) from gear (19). (36) from cage (37).
a Use a bearing puller to pull out. a Use a bearing puller to pull out.
6. Modulating clutch gear (gear E) 8. Case

1) Remove eight mounting bolts to remove Remove the outer races of taper roller bearings
cage (21) and shim (22). (10), (15) and (20) from case (39).
a Note the number and thickness of the a Use a bearing puller to pull out.
2) Remove the outer races of taper roller bear- Assembly 50-149
ings (23) and (24) from cage (21). a Adjust the preload of the taper roller bearing for
a Use a bearing puller and a press to pull the input transfer according to the following pro-
out. cedure.
3) Remove gear (25). 1) Adjust preload of bearings of A, B, C, D
4) Remove the snap ring (26), and remove the and E shafts independently.
outer race of roller bearing (27) from gear Adjust the preload along each axis according
(25). to Steps 1 to 6 below.
a Use a bearing puller to pull out. a First adjust the preload of bearings of
5) Remove the inner races of taper roller bear- shafts A and E, then remove the gears of
ings (23) and (28) from gear (25). shafts A and E to adjust the preload of
a Use a bearing puller to pull out. bearings of shafts B, C and D.
Then, install the gears of shafts A and E
7. Input gear (gear A) with the shim thickness as adjusted previ-
1) Remove the mounting bolts to remove holder ously.
(29).
2) Remove coupling (30).
3) Remove 17 mounting bolts to remove cage
(31).
4) Remove oil seal (32) from cage (31).
5) Remove the outer race of taper roller bearing
(33) from cage (31).
6) Remove spacer (34).
7) Sling and remove gear (35).
2) After the preload adjustment, check that the
gears are free from play.
Gear Reduction ratio
A to B 68/74 = 0.919
A to C 68/74 = 0.919
A to D 68/74 = 0.919
A to E 58/74 = 0.784
WA1200-6 50-149
Power train
1. Case
Install the outer races of taper roller bearings
(10), (15) and (20) to case (39).
a Using a press, press fit the outer race until its
end face comes in contact with the stepped
part of the case.
7) Use tool C1 to press fit oil seal (32) to cage

(31).
a Apply a thin film of liquid gasket (LG-5) to
the oil seal press fit surface on the cage.
After press fitting the oil seal, wipe off ex-
tra liquid gasket.
2. Input gear (gear A) a Press fit the oil seal until the flange of the
1) Install the outer race of taper roller bearing tool C1 comes in contact with the cage.
(36) to cage (37). 2 Oil seal lip:
a Using a press, press fit the outer race until Grease (G2-LI)
its end face comes in contact with the
stepped part of the cage.
2) Fit the O-ring and install shim (38) and cage
(37) with eight bolts.
a The shim is 2-piece type. To install right
and left shim packs of same thickness,
prepare them to the standard thickness in
advance.
a Standard thickness of shim pack: 2 mm
3) Install the inner races of taper roller bearings
(36) and (33) to gear (35).
a Using a press, press fit the inner race until
stepped part of the gear.
4) Install gear (35).
8) Install cage (31) with17 bolts.
a Drop transmission oil (TO30 or TO10)
about 6 cc to the sliding portion of the
bearing and rotate the bearing ten turns
to run in the bearing.
2 Mounting bolt threaded portion:
5) Install spacer (34).
Adhesive (LT-2)
3 Mounting bolt:
6) Install the outer race of taper roller bearing
245 to 309 Nm {25.0 to 31.5 kgm}
(33) to cage (31).
9) Loosen the mounting bolts of cage (37) to
a Using a press, press fit the outer race until
remove temporarily-assembled shims (38).
Tighten eight mounting bolts and retighten to
4.9 Nm {0.5 kgm}.
50-150 WA1200-6
Power train
10)Rotate the gear (35) 20 turns by hand, and 14)Using a push-pull scale, measure the turning
then check the tightening torque of the force at the tip of the gear teeth, and check
mounting bolts of cage (37). that it is within the standard value.
a Turning force of gear: 4.5 to 13.5 N {0.46
to 1.38 kg}
Or gear torque: 0.98 to 2.94 Nm {0.10 to
0.30 kgm}
a If the value falls out of the standard value,
increase or decrease the thickness of
shim pack for adjustment.
a Adjustment range of shim pack thickness:
1.3 to 2.7 mm
a Available shims: 0.15 mm, 0.2 mm and
0.5 mm
a In Steps 9) to 14), do not move case (39)
such as by turning upside down.
15)Install coupling (30) with the O-ring.

11)If the tightening torque has changed, repeat
Steps 9) and 10).
16)Install holder (29) with the bolts.
12)If the tightening torque has not changed,
Adhesive (LT-2)
3 Mounting bolt:
loosen the mounting bolts of cage (37) and
measure clearance A at three places and
824 to 1,030 Nm {84 to 105 kgm}
obtain the average.
a Measuring point of clearance: Position
marked with star
a If the dispersion of the values measured
at the three places does not fall within
0.15 mm, check whether the bearing is
correctly installed, or there is any other
cause. Take a corrective action so that
the dispersion falls in the normal range.
3. Modulating clutch gear (gear E)

(28) and (23) to gear (25).
13)Insert shim (38) of the thickness which is

reduced by 0.10 to 0.20 mm from the
average value of clearance A measured in
Step 12), and tighten cage (37) with eight
bolts.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
WA1200-6 50-151
Power train
2) Install the outer race of roller bearing (27) to 6) Using tool C5, rotate gear (25) 20 turns, and
gear (25), and secure it by using snap ring then check the tightening torque of the
(26). mounting bolts of cage (21).
7) If the tightening torque has changed, repeat

Steps 5) and 6).
3) Install gear (25). 8) If the tightening torque has not changed,

a Drop transmission oil (TO30 or TO10) loosen the mounting bolts of cage (21), insert
about 6 cc to the sliding portion of the shim (22) and tighten cage (21) with eight
bearing and rotate the bearing ten turns bolts.
to run in the bearing. a The shim is 2-piece type. To install right
4) Install the outer races of taper roller bearings and left shim packs of same thickness,
(23) and (24) to cage (21). prepare them to the standard thickness in
a Using a press, press fit the outer race until advance.
its end face comes in contact with the a Standard thickness of shim pack: 2 mm
5) Install cage (21) and tighten eight mounting 9) Using tool C5, measure the turning torque at
bolts to 4.9 Nm {0.5 kgm} without fitting shim the center of the gear, and check that it is
(22). within the standard value.
a Drop transmission oil (TO30 or TO10) a Gear turning torque: 1.76 to 2.94 Nm
about 6 cc to the sliding portion of the {0.18 to 0.30 kgm}
bearing and rotate the bearing ten turns a If the value falls out of the standard value,
to run in the bearing. increase or decrease the thickness of
1.3 to 2.7 mm
0.5 mm
50-152 WA1200-6
Power train
4. PTO gear 3 (gear B)

(20) and (18) to gear (19).

a Note that the PTO gear 2 and PTO gear 3
are different with each other, and they
have their own installed directions.
Two identification grooves are formed at
the end surface of gear (19). Check the
identification grooves, and install the gear
with the identification grooves facing the
cage (torque converter).
(The figure shows the gear as seen from
the torque converter side.)

(18) to cage (16).
4) Install cage (16) with the O-ring and tighten

eight mounting bolts to 4.9 Nm {0.5 kgm}
without fitting shim (17). 5) Using tool C3 (2/2), rotate gear (19) 20 turns,
a Drop transmission oil (TO30 or TO10) and then check the tightening torque of the
about 6 cc to the sliding portion of the mounting bolts of cage (16).
a Install the cage with the stamp "UP" up,
and check that the lubrication cast hole
"A" is at the top.

Steps 4) and 5).
WA1200-6 50-153
Power train
7) If the tightening torque has not changed, 9) Using tool C3 (2/2), measure the torque at
loosen the mounting bolts of cage (16) and the center of the gear, and check that it is
measure clearance A at three places and within the standard value.
obtain the average. a Gear torque:
a Measuring point of clearance: Position 0.98 to 2.94 Nm {0.10 to 0.30 kgm}
marked with A a If the value falls out of the standard value,
a If the dispersion of the values measured increase or decrease the thickness of
at the three places does not fall within shim pack for adjustment.
0.15 mm, check whether the bearing is a Adjustment range of shim pack thickness:
correctly installed, or there is any other 1.3 to 2.7 mm
cause. Take a corrective action so that a Available shims: 0.15 mm, 0.2 mm and
the dispersion falls in the normal range. 0.5 mm
8) Insert shim (17) of the thickness which is

bolts.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
50-154 WA1200-6
Power train
5. PTO gear 2 (gear C)

(15) and (13) to gear (14).

a Note that the PTO gear 2 and PTO gear 3
are different with each other, and they
have their own installed directions.
One identification groove is formed at the
end surface of gear (14). Check the iden-
tification grooves, and install the gear with
the identification grooves facing the cage
(torque converter).
(The figure in the lower right shows the
gear as seen from the torque converter
side.)

(13) to cage (11).

without fitting shim (12). 5) Using tool C6, rotate gear (14) 20 turns, and
a Drop transmission oil (TO30 or TO10) then check the tightening torque of the
about 6 cc to the sliding portion of the mounting bolts of cage (11).
a Install the cage with the stamp "UP" up,
and check that the lubrication cast hole
"A" is at the top.

Steps 4) and 5).
WA1200-6 50-155
Power train
7) If the tightening torque has not changed, 9) Using tool C6, measure the torque at the
loosen the mounting bolts of cage (11) and center of the gear, and check that it is within
measure clearance A at three places and the standard value.
obtain the average. a Gear torque:
a Measuring point of clearance: Position 0.98 to 2.94 Nm {0.10 to 0.30 kgm}
marked with A a If the value falls out of the standard value, in-
a If the dispersion of the values measured crease or decrease the thickness of shim
at the three places does not fall within pack for adjustment.
0.15 mm, check whether the bearing is a Adjustment range of shim pack thickness:
correctly installed, or there is any other 1.3 to 2.7 mm
cause. Take a corrective action so that a Available shims: 0.15 mm, 0.2 mm and 0.5
the dispersion falls in the normal range. mm
a In Steps 4) to 9), do not move case (39) such
as by turning upside down.
8) Insert shim (12) of the thickness which is

bolts.
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
50-156 WA1200-6
Power train
6. PTO gear 1 (gear D) 8) Using tool C3 (1/2), rotate gear (8) 20 turns,
1) Install the inner races of taper roller bearings and then check the tightening torque of the
(10) and (5) to gear (8). mounting bolts of cage (3).
2) Install snap ring (9) to gear (8).

4) Install snap ring (7) to coupling (6).
5) Install coupling (6).

Steps 7) and 8).
(5) to cage (3).
10)If the tightening torque has not changed,
loosen the mounting bolts of cage (3) and
measure clearance A at three places and
obtain the average.
a Measuring point of clearance: Position
marked with A
a If the dispersion of the values measured
without fitting shim (4).
at the three places does not fall within
0.15 mm, check whether the bearing is
correctly installed, or there is any other
cause. Take a corrective action so that
the dispersion falls in the normal range.
WA1200-6 50-157
Power train
11)Insert shim (4) of the thickness which is 8. Speed sensor

reduced by 0.10 to 0.20 mm from the Install speed sensor (1) and secure it with the
average value of clearance A measured in lock nut.
Step 10), and tighten cage (3) with eight 2 Threaded portion of sensor:
bolts. Liquid gasket (LG-5)
a Apply the speed sensor end to the side face
of the input gear located inside of the PTO
and transfer lightly, return the sensor from
that position by 1/2 to 3/4 turns, and secure
with the lock nut.
3 Locknut:
49.0 to 68.6 Nm {5 to 7 kgm}
12)Using tool C3 (1/2), measure the torque at

the center of the gear, and check that it is
within the standard value.
a Gear torque:
0.98 to 2.94 Nm {0.10 to 0.30 kgm}
a If the value falls out of the standard value,
increase or decrease the thickness of
1.3 to 2.7 mm
0.5 mm
7. Cover
Fit the gasket and install cover (2) with 12 bolts.
50-158 WA1200-6
Power train
Disconnection and connection of transmission assembly, transfer, and parking brake assembly
Disconnection and connection of transmission assembly, transfer, and

parking brake assembly 50-159
WA1200-6 50-159
Power train
a When re-assembling the transmission assem- 5. Speed clutch valve assembly

bly, or the transfer and parking brake assem- 1) Remove four mounting bolts, then remove
blies, O-rings, seals, and other consumable 1st clutch ECMV assembly (16) and bypass
parts must be replaced with new ones. Prepare fill valve assembly (17).
the following kit components. a Two kinds of mounting bolts different in
KIT No.: 42C-15-05280 length are used. Put matchmarks to indi-
a For details of KIT No., see the end of this sec- cate their installed positions.
tion. 2) Remove four mounting bolts, then remove
two assemblies, 2nd clutch ECMV assembly
Disconnection 50-160 and 3rd clutch ECMV assembly (18).
1. Preparation work a Two kinds of mounting bolts different in
Set Raise the assembly with the transfer vertical length are used. Put matchmarks to indi-
and support the transmission with blocks, etc. so cate their installed positions.
that the transmission is kept level.
6. Lubrication relief valve assembly
2. Lubrication tube Remove three mounting bolts, then remove
1) Remove the two joints from each lubrication lubrication relief valve assembly (19).
tube, and remove lubrication tubes (1), (2), a Two kinds of mounting bolts different in
(3), (4), and (5). length are used. Put matchmarks to indicate
a Remove the tube clamp. their installed positions.
2) Remove two mounting bolts to remove block
(6). 7. Valve seat
3) Remove two mounting bolts to remove block 1) Remove four mounting bolts and remove
(7). valve seat (20).
a Two kinds of mounting bolts different in
3. Oil filter assembly length are used. Put matchmarks to indi-
1) Remove one mounting bolt and three sets of cate their installed positions.
nuts and stud bolts, then remove cover (8) 2) Remove valve seat (21).
and four spacers (9). 3) Remove 14 mounting bolts and remove valve
2) Remove three mounting bolts, then remove seat (22).
oil filter assembly (10) and cover (11).
8. Breather
4. FR clutch valve assembly 1) Remove two breathers (23) and remove two
1) Remove four mounting bolts, then remove elbows (24).
reverse clutch ECMV assembly (12), and 2) Remove four mounting bolts and flange (25).
bypass fill and drain valve assembly (13).
length are used. Put matchmarks to indi-
cate their installed positions.
2) Remove four mounting bolts, then remove
forward clutch ECMV assembly (14) and
bypass fill valve assembly (15).
length are used. Put matchmarks to indi-
cate their installed positions.
50-160 WA1200-6
Power train
9. Transmission assembly, and transfer and Connection 50-161

parking brake assembly 1. Preparation work
1) Sling transmission assembly (26). Place the transfer vertical and support it with
2) Remove 23 mounting bolts, and disconnect blocks.
transmission assembly (26) from transfer
and parking brake assembly (27). 2. Strainer
k When removing the transmission, pay 1) Install four cases (32) with the O-ring.
careful attention so that the transfer 2 O-ring on periphery:
and parking brake assembly does not Grease (G2-LI)
fall over. 2) Install four magnets (31) and four springs
a Move the transmission to the input shaft (30).
side until the output shaft of transmission 3) Install four covers (29) with the O-ring by
comes off the transfer. using four bolts each.
a Place the removed transmission assem- 4) Install valve seat (28) with the O-ring by using
bly on the block with the input shaft side two bolts.
up. 2 O-ring:
a For procedures for disassembling the Grease (G2-LI)
transmission, see "Assembly and disas-
sembly of transmission". 3. Transmission assembly, and transfer and
a For procedures for disassembling the parking brake assembly
transfer and parking brake, see "Assem- 1) Fit the O-ring to the joint portion (26) of
bly and disassembly of transfer", and "As- transfer and parking brake assembly (27)
sembly and disassembly of parking connecting with transmission assembly (26).
brake". 2 O-ring:
Grease (G2-LI)
10. Strainer 2) Sling transmission assembly (26) and install
1) Remove two mounting bolts to remove drain it to transfer assembly (27) with 23 bolts.
plug (28). k When installing the transmission, pay
2) Remove four mounting bolts from each cover careful attention so that the transfer
and remove four covers (29). and parking brake assembly does not
3) Remove four springs (30) and four magnets fall over.
(31). a After installing the transmission, support
4) Remove four cases (32). the bottom of the transmission with
blocks.
4. Breather
1) Install flange (25) with four bolts.
2 Mating face on flange with case:
2) Install two elbows (24) and install two
breathers (23).
2 Elbow and breather:
WA1200-6 50-161
Power train
5. Valve seat 2) Install bypass fill valve assembly (17) with

1) Install valve seat (22) with O-rings by using O-rings and 1st clutch ECMV assembly (16)
14 bolts. with the O-rings by using four bolts.
3 Hexagon socket head bolt (six a Two kinds of mounting bolts different in
bolts): length are used. Check their installed po-
58.8 to 73.5 Nm {6.0 to 7.5 kgm} sitions with matchmarks that were put at
2) Install valve seat (21) with O-rings. the time of disassembly.
3) Install valve seat (20) with O-rings by using 3 Mounting bolt:
four bolts. 27.4 to 34.3 Nm {2.8 to 3.5 kgm}
length are used. Check their installed po- 8. FR clutch valve assembly
sitions with matchmarks that were put at a Before installation, make sure that you have
the time of disassembly. picked up the FR clutch ECMV assembly and
3 Mounting bolt: it is not the speed clutch ECMV assembly.
58.8 to 73.5 Nm {6.0 to 7.5 kgm} The FR clutch ECMV assembly uses hexag-
onal socket head bolts as cover mounting
6. Lubrication relief valve assembly bolts.
Install lubrication relief assembly (19) with 1) Install bypass fill valve assembly (15) with
O-rings by using three bolts. O-rings and forward clutch ECMV assembly
a Two kinds of mounting bolts different in (14) with the O-rings by using four bolts.
length are used. Check their installed posi- a Two kinds of mounting bolts different in
tions with matchmarks that were put at the length are used. Check their installed po-
time of disassembly. sitions with matchmarks that were put at
3 Mounting bolt: the time of disassembly.
58.8 to 73.5 Nm {6.0 to 7.5 kgm} 3 Mounting bolt:
27.4 to 34.3 Nm {2.8 to 3.5 kgm}
7. Speed clutch valve assembly 2) Install bypass fill valve assembly (13) with
a Before installation, make sure that you have O-rings and reverse clutch ECMV assembly
picked up the speed clutch ECMV assembly (12) with the O-rings by using four bolts.
and it is not the FR clutch ECMV assembly. a Two kinds of mounting bolts different in
The speed clutch ECMV assembly uses hex- length are used. Check their installed po-
agonal head bolts as cover mounting bolts. sitions with matchmarks that were put at
1) Install two assemblies with O-rings, 3rd the time of disassembly.
clutch ECMV assembly and 2nd clutch 3 Mounting bolt:
ECMV assembly (18) by using four bolts 27.4 to 34.3 Nm {2.8 to 3.5 kgm}
each. 9. Oil filter
a Two kinds of mounting bolts different in 1) Install cover (11) with O-rings and oil filter
length are used. Check their installed po- assembly (10) by using three bolts.
sitions with matchmarks that were put at 3 Mounting bolt:
the time of disassembly. 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3 Mounting bolt: 2) Install three studs, then install four spacers
27.4 to 34.3 Nm {2.8 to 3.5 kgm} (9) and cover (8) by using one bolt and three
nuts.
10. Lubrication tube

1) Install block (7) by using two bolts.
2) Install block (6) by using two bolts.
3) Fit the gasket and install lubrication tubes (5),
(4), (3), (2), (1) by using two joints each.
3 Joint:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
50-162 WA1200-6
Power train
Service kit parts list 50-163 Service kit parts list 50-163
KIT No.: 42C-15-05280 (Connection service kit for KIT No.: 42C-15-05280 (Connection service kit for
transmission and transfer assemblies) transmission and transfer assemblies)
Fig. No.: Y0 Y99-0000002 (K06) (Transfer case) Fig. No.: Y0 Y99-0000002 (K06) (Transfer case)
5 42C-15-18240 O-RING 1 8 07000-72135 O-RING 1
7 07000-72130 O-RING 8 10 07000-75185 O-RING 1
13 07000-72115 O-RING 4 23 569-15-59110 O-RING 1
21 07000-72125 O-RING 2 26 07000-72135 O-RING 1
22 07000-73045 O-RING 1
23 07000-72070 O-RING 1
WA1200-6 50-163
Power train
Service kit parts list 50-164 Service kit parts list 50-164
KIT No.: 42C-15-05280 (Connection service kit for KIT No.: 42C-15-05280 (Connection service kit for
transmission and transfer assemblies) transmission and transfer assemblies)
Fig. No.: Y0 Y99-0000006 (K06) (Transfer output Fig. No.: Y0 Y99-0000006 (K06) (Transmission pip-
shaft) ing)
4 07000-75210 O-RING 1 34 07000-73028 O-RING 1
8 07012-50140 SEAL 1
9 562-15-39970 O-RING 2
14 42C-15-05010 SHIM KIT 1
20 42C-15-13332 SEAL 1
50-164 WA1200-6
Power train
Service kit parts list 50-165

KIT No.: 42C-15-05280 (Connection service kit for
transmission and transfer assemblies)
Fig. No.: Y0 Y99-0000002 (K06) (Parking brake)
Index Part No. Part name Q'ty
9 07000-75495 O-RING 1
12 175-15-59240 RING 1
13 562-15-19550 RING 1
22 07000-75495 O-RING 1
24 42C-15-13332 SEAL 1
25 07012-50140 SEAL 1
32 07000-72018 O-RING 1
33 07000-72016 O-RING 1
34 07000-73028 O-RING 1
36 07002-61023 O-RING 1
WA1200-6 50-165
Power train
Disassembly and assembly of transmission assembly
Disassembly and assembly of transmission assembly 50-16
50-166 WA1200-6
Power train
WA1200-6 50-167
Power train
50-168 WA1200-6
Power train
WA1200-6 50-169
Power train
Special tools 50-170 5) Remove eight mounting bolts to remove

cage (10).
New/redesign
a Use forcing screws to pull out.
Necessity
Sketch
Sym-
Q'ty
Part No. Part name 6) Remove two seal rings (11) from cage (10).
bol
7) Remove snap ring (12) and then remove
gear (13).
1 SMT-890-1410 Socket t 1 Q 8) Remove snap ring (14).
D 9) Remove shaft (15).
8 SMT-890-4100 Guide t 1 Q
10)Remove seal ring (16) from shaft (15).
Disassembly 50-170 11)Remove snap ring (17) and then remove
1. Preparation work gear (18).
Set the transmission assembly with the input 12)Remove ball bearing (19) from shaft (15).
shaft up on the block. a Use a press to pull out.
13)Remove shaft (20) and ball (21) from carrier
2. Case (22).
1) Remove seven sleeves (1). a Remove four sets.
a To remove the sleeve, apply a bearing 14)Remove gear (23), and then remove two
puller to the groove in the inner periphery needle bearings (24) and two thrust washers
of each sleeve. (25).
2) Remove 23 mounting bolts to remove case a Remove four sets.
(2). 15)Remove the inner race of roller bearing (26).
3. Housing
Remove 24 long bolts and 6 short bolts to 5. Reverse clutch plate and disc
remove housing (3). 1) Remove six springs (27).
a The length of spring differs depending on
4. Input shaft, reverse clutch carrier, reverse sun clutch types. Attach a tag to each spring
gear assembly to identify its mounting position.
1) Sling the end of the input shaft to remove 2) Remove eight plates (28) and seven discs
input shaft, reverse clutch carrier, and (29) alternately while removing 48 springs
reverse sun gear assembly (4). (30).
a Since the inner and outer races of the ta-
per roller bearing at the bottom of the car- 6. Reverse clutch ring gear
rier are separated, lift the assembly Remove ring gear (31).
straight up, taking care not to pry the rac-
es.
2) Remove snap ring (5) and then remove
spacer (6).
3) Remove cage (7).
a Use a puller to pull out.
4) Remove ball bearings (8) and (9) from cage
(7).
50-170 WA1200-6
Power train
7. Reverse clutch housing and piston 12. 3rd clutch plate and disc
1) Remove housing (32). 1) Remove six springs (50).
a Remove it and the piston as a unit. a The length of spring differs depending on
2) Remove piston (33) from housing (32). clutch types. Attach a tag to each spring
3) Remove seal ring (34) from housing (32). to identify its mounting position.
4) Remove seal ring (35) from piston (33). 2) Remove five plates (51) and four discs (52)
while removing 30 springs (53).
8. Coupler ring gear
1) Remove eight mounting bolts to remove 13. Forward clutch and 3rd clutch carrier assembly
plate (36). 1) Remove four mounting bolts to remove collar
2) Remove ring gear (37). (54).
3) Remove snap ring (38) from ring gear (37). 2) Remove two seal rings (55) from collar (54).
3) Sling and remove forward clutch and 3rd
9. Forward clutch plate and disc clutch carrier assembly (56).
1) Remove six pins (39) and 12 pins (40). 4) Remove snap ring (57), and then remove ball
a The length of pin differs depending on bearing (58) and gear (59).
clutch types. Attach a tag to each pin to a Use a press to pull out.
identify its mounting position. 5) Remove collar (60) from ball bearing (58).
2) Remove six springs (41). a Use a press to pull out.
a The length of spring differs depending on 6) Remove shaft (62) and ball (63) from carrier
clutch types. Attach a tag to each spring (64).
to identify its mounting position. a Remove four sets.
3) Remove nine plates (42) and eight discs (43) 7) Remove gear (65), and then remove two
alternately while removing 72 springs (44). needle bearings (66) and two thrust washers
(67).
10. Forward clutch ring gear a Remove four sets.
Remove ring gear (45). 8) Remove the outer race of roller bearing (26)
from carrier (64).
11. Forward clutch housing and piston a Use a bearing puller to pull out.
1) Remove housing (46).
a Remove it and the piston as a unit. 14. 3rd clutch ring gear
2) Remove piston (47) from housing (46). 1) Remove eight mounting bolts to remove
3) Remove seal ring (48) from housing (46). plate (68).
4) Remove seal ring (49) from piston (47). 2) Remove ring gear (69).
3) Remove snap ring (70) from ring gear (69).
WA1200-6 50-171
Power train
15. 3rd clutch housing and piston 20. 2nd clutch carrier and 1st clutch assembly
1) Remove housing (71). 1) Remove 2nd clutch carrier and 1st clutch
a Remove it and the piston as a unit. assembly (87).
2) Remove piston (72) from housing (71). a Apply a puller to the bolt hole in the carrier
3) Remove seal ring (73) from housing (71). to pull out the assembly.
4) Remove seal ring (74) from piston (72). 2) Remove 30 mounting bolts to remove cage
(88).
16. 2nd clutch plate and disc 3) Remove snap ring (89), and then remove
1) Remove six springs (75). spacer (90) from cage (88).
a The length of spring differs depending on a Remove the snap ring while pressing the
clutch types. Attach a tag to each spring springs with a press.
to identify its mounting position. 4) Remove three springs (91) from cage (88).
2) Remove six pins (76) and 12 pins (77). 5) Remove piston (92) from cage (88).
a The length of pin differs depending on 6) Remove seal ring (93) from piston (92).
clutch types. Attach a tag to each pin to 7) Remove snap ring (94), and then remove ball
identify its mounting position. bearing (95) from cage (88).
3) Remove four plates (78) and three discs (79) a Use a bearing puller to pull out.
alternately while removing 24 springs (80). 8) Remove snap ring (96), and then remove
collar (97) from cage (88).
17. 2nd clutch ring gear 9) Remove ball bearing (98) from cage (88).
Remove ring gear (81). a Use a bearing puller to pull out.
10)Remove seal rings (99) and (100) from cage
18. 2nd clutch housing (88).
1) Remove housing (82). 11)Remove hub (101).
a Remove it and the piston as a unit. 12)Remove two seal rings (102) from hub (101).
2) Remove piston (83) from housing (82). 13)Remove nine discs (103), eight plates (104),
3) Remove seal ring (84) from housing (82). and nine springs (105) alternately.
4) Remove seal ring (85) from piston (83). 14)Remove snap ring (106) from carrier (107).
15)Remove shaft (108) and ball (109) from
19. 2nd clutch sun gear carrier (107).
Remove gear (86). a Remove four sets.
16)Remove gear (110), and then remove two
needle bearings (111) and two thrust
washers (112).
a Remove four sets.
21. Output shaft assembly and housing

1) Remove six mounting bolts to remove output
shaft assembly (113) from housing (114).
a Use forcing screws to pull out.
2) Remove snap ring (115), and then remove
cage (116) from shaft (117).
3) Remove seal ring (118) from cage (116).
4) Remove snap ring (119), and then remove
ball bearing (120) from shaft (117).
5) Remove seal ring (121) from shaft (117).
50-172 WA1200-6
Power train
Assembly 50-173
Precautions for assembly 50-173
a Use new O-rings, seal rings, and thrust washers.

1. Assembling output shaft
q Precautions for assembling output shaft
1) Temporarily assemble output shaft (117) as
shown in the figure. Then, measure the clear-
ance "A" between collar (54) and 3rd gear
(59) all around, and check that the measure-
ments are 0.1 mm or more.
2) Before disassembling the above temporarily
assembled unit, put marks on all parts with a
marker pen so that they are assembled in
correct circumferential directions at actual
assembly.
3) At actual assembly, match the marks.
q When using old parts

1) When reusing old parts, temporarily
assemble output shaft (117) as shown in the
figure, and measure clearance "A" between
collar (54) and 3rd gear (59) according to the
procedure shown in the table.
WA1200-6 50-173
Power train
2) Repairing collar 2) Fix insertion tool D8 to pinion shaft (20) with

1] Grind the end face of collar (54) bolts.
(19M-15-12850) so that clearance "A" is a Insertion tool D8 prevents the rollers of
0.1 mm. bearings (24) from falling down inside, al-
2] After re-assembling, insert a gauge into lowing smooth insertion of the pinion
the clearance between 3rd gear (59) and shaft.
collar (54), and check that the clearance
is 0.1 mm.
3] If the clearance does not reach 0.1 mm,
return to step i), and repeat the proce-
dure.
D: Grinding surface
E: Surface roughness of the grinding
surface shall be RR (25S or less).
3) Cool down pinion shaft (20) with dry ice, and

insert the shaft with ball (21) into carrier (22).
2. Assembling reverse clutch carrier

1) Place carrier (22) (42C-15-12331) with the
input side (with a ball groove) up. Install bear-
ings (24) to planetary gear (23) for R clutch.
Set the planetary gear with thrust washer
(25) on both sides to in carrier (22).
a Align the holes in the planetary gear,
bearings, and thrust washers with the car-
rier hole so that pinion shaft (20)
(19M-15-12531) is inserted smoothly.
50-174 WA1200-6
Power train
4) Loosen bolts of tool D8, and remove tool D8 2) Fix insertion tool D8 to pinion shaft (62) with
from pinion shaft (20). bolts.
a Insertion tool D8 prevents the rollers of
bearings (66) from falling down inside, al-
lowing smooth insertion of the pinion
shaft.
3. Assembling forward and 3rd clutch carrier

1) Place carrier (64) (19M-15-12325) with the
input side (with a ball groove) up. Install bear-
ings (66) to planetary gear (65) for the 3rd
clutch. Set the planetary gear with thrust 3) Cool down pinion shaft (62) with dry ice, and
washer (67) on both sides to carrier (64). insert the shaft with ball (63) into carrier (64).
In the same way, set planetary gear (65),
bearings (66), and thrust washers (67) for the
F clutch to the carrier.
a Align the holes in the planetary gear,
bearings, and thrust washers with the car-
rier hole so that pinion shaft (62)
(19M-15-00092) is inserted smoothly.
4) Loosen bolts of tool D8, and remove tool D8

from pinion shaft (62).
WA1200-6 50-175
Power train
5) Install plate (36) to carrier (64), temporarily fix 6) Reverse the forward and 3rd clutch carrier
it with bolts, and reverse the carrier assembly assembly, and remove the temporarily fixed
so that pinion shaft (62) and ball (63) are not plate (36).
removed. a This step is required to use the tap hole
"F" for installing plate (36) as a hanging
tap at assembly of transmission.
4. Assembling 3rd clutch gear

1) Install 3rd clutch sun gear (59) to forward and
3rd clutch carrier (64). 5. Assembling 2nd clutch carrier
2) Using the push tool, press fit bearing (58) to 1) Place 2nd clutch carrier (107)
collar (60). (19M-15-12312) with the output side (with a
3) Press fit the assembly of bearing (58) and ball groove) up. Install bearings (111) to plan-
collar (60) to forward and 3rd carrier (64). etary gear (110) for the 2nd clutch. Set the
4) Install snap ring (57). planetary gear with thrust washer (112) on
5) Install plate (122) to forward and 3rd carrier both sides to carrier (107).
(64) with bolts (123) and washers. a Align the holes in the planetary gear,
2 Mounting bolt: bearings, and thrust washers with the car-
Adhesive (LT-2) rier hole so that pinion shaft (108) is in-
3 Mounting bolt: serted smoothly.
98 to 123 Nm {10 to 12.5 kgm} 2) Cool down pinion shaft (108) with dry ice, and
insert the shaft with ball (109) into carrier
(107).
3) Install snap ring (124).
50-176 WA1200-6
Power train
Assembly 50-17 3) Install snap ring (106) in carrier (107).

4) Install nine discs (103), eight plates (104),
1. Output shaft assembly and housing and nine springs (105) in carrier (107) alter-
1) Install seal ring (121) to shaft (117). nately.
a Use new seal rings. 5) Install two seal rings (102) to hub (101).
2 Seal ring: 2 Seal ring:
Grease (G2-LI) Grease (G2-LI)
2) Install ball bearing (120) to shaft (117), and 6) Install hub (101) in carrier (107).
secure it by using snap ring (119). 7) Install seal rings (100) and (99) to cage (88).
a Using a press, press fit the bearing until 2 Seal ring:
the end face of inner race comes in con- Grease (G2-LI)
tact with the stepped part of the shaft. a Seal ring (100) has its installed direction.
3) Install seal ring (118) to cage (116). Install the seal ring as shown in the draw-
2 Seal ring: ing below.
Grease (G2-LI)
4) Install cage (116) to shaft (117), and secure
it by using snap ring (115).
a Using a press, press fit the outer race of
bearing until its end face comes in contact
with the stepped part of the cage.
5) Install output shaft assembly (113) to
housing (114) with six bolts.
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
2. 2nd clutch carrier and 1st clutch assembly

a See item 2 in "Precautions for assembly". 8) Install ball bearing (98) to cage (88).
1) Set two thrust washers (112) and two needle a Using a press, press fit the outer race until
bearings (111) to gear (110), and install the its end face comes in contact with the
gear to carrier (107). stepped part of the cage.
a Take care not to dent the thrust washers. 9) Install collar (97) to cage (88), and secure it
a Install four sets. by using snap ring (96).
2) Install shaft (108) with ball (109) to carrier 10)Install ball bearing (95) to cage (88), and
(107). secure it by using snap ring (94).
a Aligning the ball with the carrier groove, a Using a press, press fit the outer race until
press fit the shaft by using a press until its end face comes in contact with the
the shaft is flush with the carrier. stepped part of the cage.
a Install four sets.
WA1200-6 50-177
Power train
11)Install seal ring (93) to piston (92). 4. 2nd clutch housing

2 Seal rings: 1) Install seal ring (85) to piston (83).
Grease (G2-LI) 2 Seal rings:
a The seal ring has its installed direction. Grease (G2-LI)
Install the seal ring as shown in the draw- a The seal ring has its installed direction.
ing below. Install the seal ring as shown in the draw-
ing below.
12)Install piston (92) to cage (88).

13)Install three springs (91) to cage (88). 2) Install seal ring (84) to housing (82).
14)Install spacer (90) and secure it by using 2 Seal rings
snap ring (89). Grease (G2-LI)
a Using a press, compress the spring, and a The seal ring has its installed direction.
install the spacer and snap ring. Install the seal ring as shown in the draw-
a Load at installed length of spring: 1,697 N ing below.
{173 kg}
15)Install cage (88) to carrier (107) with 30 bolts.
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
16)Install 2nd clutch carrier and 1st clutch
assembly (87) to the output shaft.
a Using a press, press fit the ball bearing
until the end face of inner race comes in
contact with the stepped part of the shaft.
3. 2nd clutch sun gear

Install gear (86).
3) Install piston (83) to housing (82).
4) Install housing (82).
5. 2nd clutch ring gear

Install ring gear (81).
50-178 WA1200-6
Power train
6. 2nd clutch plate and disc 9. Forward and 3rd clutch carrier assembly
1) Install four plates (78) and three discs (79) 1) Install the outer race of roller bearing (26) to
alternately while installing 24 springs (80). carrier (64).
2) Install 12 pins (77) and six pins (76). a Using a press, press fit the outer race until
a The length of pin differs depending on its end face comes in contact with the
clutch types. Check the length of pin be- stepped part of the carrier.
fore installation. 2) Set two thrust washers (67) and two needle
a Pin length (77): 208 mm, (76): 223 mm bearings (66) to gear (65), and install the
3) Install six springs (75). gear to carrier (64).
a The length of spring differs depending on a Take care not to dent thrust washers.
clutch types. Check the length of spring a Install four sets.
before installation. 3) Install shaft (62) with ball (63) to carrier (64).
a Free length of spring: 56.9 mm a Aligning the ball with the carrier groove,
press fit the shaft by using a press until
7. 3rd clutch housing and piston the shaft is flush with the carrier.
1) Install seal ring (74) to piston (72). a Install four sets.
2 Seal rings: 4) Install plate (59) to carrier (64).
Grease (G2-LI) 5) Press fit collar (60) into ball bearing (58) with
a The seal ring has its installed direction. a press.
Check the installed direction before in- a Using a press, press fit the collar until the
stallation (similarly to that for 2nd clutch). stepped part of the collar comes in con-
2) Install seal ring (73) to housing (71). tact with the end face of the inner race.
2 Seal rings: 6) Install ball bearing (58) to carrier (64), and
Grease (G2-LI) secure it by using snap ring (57).
a The seal ring has its installed direction. a Using a press, press fit the bearing until
Check the installed direction before in- the end face of the outer race comes in
stallation (similarly to that for 2nd clutch). contact with the stepped part of the carri-
3) Install piston (72) to housing (71). er.
4) Install housing (71). 7) Install forward clutch and 3rd clutch carrier
assembly (56).
8. 3rd clutch ring gear 8) Install two seal rings (55) to collar (54).
1) Install snap ring (70) to ring gear (69). a Use new seal rings.
2) Install ring gear (69). 2 Seal ring:
3) Install plates (68) with eight bolts. Grease (G2-LI)
2 Mounting bolt threaded portion: 9) Install collar (54) by using four bolts.
Adhesive (LT-2) 2 Mounting bolt threaded section:
3 Mounting bolt: Adhesive (LT-2)
98 to 123 Nm {10.0 to 12.5 kgm} 3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
WA1200-6 50-179
Power train
10. 3rd clutch plate and disc 14. Coupler ring gear
1) Install five plates (51) and four discs (52) 1) Install snap ring (38) to ring gear (37).
alternately while installing 30 springs (53). 2) Install ring gear (37).
2) Install six springs (50). 3) Install plates (36) with eight bolts.
a The length of spring differs depending on 2 Mounting bolt threaded section:
clutch types. Check the length of the Adhesive (LT-2)
springs before installation. 3 Mounting bolt:
a Free length of spring: 68.8 mm 98 to 123 Nm {10.0 to 12.5 kgm}
11. Forward clutch housing and piston 15. Reverse clutch housing and piston
1) Install seal ring (49) to piston (47). 1) Install seal ring (35) to piston (33).
2 Seal rings: 2 Seal rings:
a The seal ring has its installed direction. a The seal ring has its installed direction.
Check the installed direction before in- Check the installed direction before in-
stallation (similarly to that for 2nd clutch). stallation (similarly to that for 2nd clutch).
2) Install seal ring (48) to housing (46). 2) Install seal ring (34) to housing (32).
2 Seal rings: 2 Seal rings:
a The seal ring has its installed direction. a The seal ring has its installed direction.
Check the installed direction before in- Check the installed direction before in-
stallation (similarly to that for 2nd clutch). stallation (similarly to that for 2nd clutch).
3) Install piston (47) to housing (46). 3) Install piston (33) to housing (32).
4) Install housing (46). 4) Install housing (32).
12. Forward clutch ring gear 16. Reverse clutch ring gear
Install ring gear (45). Install ring gear (31).
13. Forward clutch plate and disc
1) Install nine plates (42) and eight discs (43) 17. Reverse clutch plate and disc
alternately while installing 72 springs (44). 1) Install eight plates (28) and seven discs (29)
2) Install six springs (41). alternately while installing 48 springs (30).
a The length of spring differs depending on 2) Install six springs (27).
clutch types. Check the length of the a The length of spring differs depending on
springs before installation. clutch types. Check the length of the
a Free length of spring: 168 mm springs before installation.
3) Install 12 pins (40) and six pins (39). a Free length of spring: 133 mm
a The length of pin differs depending on
clutch types. Check the length of pins be-
fore installation.
a Pin length (40): 315 mm, (39): 315 mm
50-180 WA1200-6
Power train
18. Input shaft, reverse clutch carrier, reverse clutch 10)Install cage (10) to gear (22) by using eight
sun gear assembly bolts.
a See item 2 in "Precautions for assembly". 2 Mounting bolt threaded section:
1) Install the inner race of roller bearing (26) to Adhesive (LT-2)
carrier (22). 3 Mounting bolt:
a Using a press, press fit the inner race until 98 to 123 Nm {10.0 to 12.5 kgm}
its end face comes in contact with the 11)Install ball bearing (9) to cage (7).
stepped part of the carrier. a Using a press, press fit the inner race until
2) Set two thrust washers (25) and two needle its end face come in contact with the
bearings (24) to gear (23), and install the stepped part of the cage.
gear to carrier (22). 12)Install cage (7) to cage (10).
a Take care not to dent thrust washers. a Using a press, press fit the outer race until
a Install four sets. its end face comes in contact with the
3) Install shaft (20) with ball (21) to carrier (22). stepped part of the cage.
a Aligning the ball with the carrier groove, 13)Using tool D1, install ball bearing (8) to cage
press fit the shaft by using a press until (7).
the shaft is flush with the carrier. a For tool D1, see the "Sketches of special
a Install four sets. tools".
4) Install ball bearing (19) to shaft (15). a Using a press, press fit the inner and out-
a Using a press, press fit the bearing until er races of the ball bearing at the same
the end face of the inner race comes in time until the end face of the outer race
contact with the stepped part of the shaft. comes in contact with the stepped part of
5) Install gear (18) and secure it with snap ring the cage.
(17). 14)Install spacer (6) and secure it with snap ring
6) Install shaft (15) to carrier (22). (5).
a Using a press, press fit the outer race of 15)Install seal ring (16) to shaft (15).
the ball bearing until its end face comes in a Use a new seal ring.
contact with the stepped part of the carri- 2 Seal ring:
er. Grease (G2-LI)
7) Install snap ring (14). 16)Sling the end of the input shaft to install input
8) Install gear (13) and secure it with snap ring shaft, reverse clutch carrier, and reverse
(12). clutch sun gear assembly (4).
9) Install two seal rings (11) to cage (10). a Since the inner and outer races of the roll-
2 Seal ring: er bearing at the bottom of the carrier are
Grease (G2-LI) combined together, lower the assembly
straight down, taking care not to pry the
races.
19. Housing
Install housing (3) with 24 long bolts and six
short bolts.
2 Threaded portion of short bolt:
Adhesive (LT-2)
3 Long bolt:
353 to 392 Nm {36 to 40 kgm}
3 Short bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
20. Case
1) Install case (2) by using 23 bolts.
3 Mounting bolt:
490 to 608 Nm {50 to 62 kgm}
2) Install seven sleeves (1) with the O-ring.
WA1200-6 50-181
Power train

KIT No.: 42C-15-05051 (Service kit for assembling KIT No.: 42C-15-05051 (Service kit for assembling
transmission) transmission)
Fig.No.: Y0 Y99-0000002 (K03) (1st clutch and 2nd Fig.No.: Y0 Y99-0000002 (K03) (Housing)
housing) Index Part No. Part name Q'ty
Index Part No. Part name Q'ty 3 19M-15-19220 RING 1
3 562-15-19320 RING 1 6 19M-15-19250 RING 1
4 198-15-29280 RING 1 11 19M-15-19230 RING 1
7 426-15-19220 RING 1 13 19M-15-19240 RING 1
17 19M-15-19280 RING 2 20 19M-15-19220 RING 1
26 19M-15-19220 RING 1 22 19M-15-19250 RING 1
28 19M-15-19250 RING 1
50-182 WA1200-6
Power train

Fig.No.: Y0 Y99-0000002 (K03) (Carrier) Fig.No.: Y0 Y99-0000002 (K03) (Input and output
Index Part No. Part name Q'ty shafts)
50 19M-15-19280 RING 2 Index Part No. Part name Q'ty
15 195-15-39260 RING 2
WA1200-6 50-183
Power train

Fig.No.: Y0 Y99-0000002 (K07) (Control valve) Fig.No.: Y0 Y99-0000002 (K07) (Control valve)
3 07002-61623 O-RING 3 9 07000-72020 O-RING 2
4 07002-61623 O-RING 7 11 07000-02012 O-RING 2
5 07002-62034 O-RING 7 12 42C-15-15980 O-RING 2
6 07002-62034 O-RING 1 13 07000-12016 O-RING 2
7 07000-73032 O-RING 2 14 07000-02018 O-RING 2
8 07000-73048 O-RING 1 15 203-60-62190 O-RING 2
9 07000-72018 O-RING 1
13 07000-72018 O-RING 7
14 07000-72021 O-RING 8
20 07000-72018 O-RING 6
21 07000-72021 O-RING 5
50-184 WA1200-6
Power train

transmission)) transmission)
Fig.No.: Y0 Y99-0000002 (K07) (Control valve) Fig.No.: Y0 Y99-0000002 (K07) (Control valve filter)
(Drain) Index Part No. Part name Q'ty
Index Part No. Part name Q'ty 2 170-09-17130 O-RING 1
10 07000-72020 O-RING 2 3 07000-02080 O-RING 1
12 07000-02012 O-RING 2 6 07002-61823 O-RING 1
13 42C-15-15980 O-RING 2 21 07002-63034 O-RING 1
14 07000-12016 O-RING 2 23 07002-62034 O-RING 1
15 07000-02018 O-RING 2
16 203-60-62190 O-RING 2
20 07002-61823 O-RING 2
WA1200-6 50-185
Power train

Fig.No.: Y0 Y99-0000002 (K07) (Lubrication valve) Fig.No.: Y0 Y99-0000002 (K01) (ECMV)
3 07002-61023 O-RING 1 2* 561-15-55630 SHIM 3
6 07002-62434 O-RING 1 5* 07000-73025 O-RING 1
5* 07000-73028 O-RING 1
5* 07000-73035 O-RING 1
5* 07000-73018 O-RING 1
5* 07002-61023 O-RING 1
a One transmission unit (equipped with five ECM-
Vs) requires five sets of components shown in
the table above.
50-186 WA1200-6
Power train
Disassembly and assembly of transfer
Disassembly and assembly of transfer 50-187
WA1200-6 50-187
Power train
50-188 WA1200-6
Power train
Special tools 50-189 4) Install the two pairs of removed bolts and
washers (12) into the plug holes.
New/redesign
a Tighten the two pairs of bolts and wash-
Necessity
Sketch
Sym-
Q'ty
Part No. Part name ers slowly and alternately to move the pis-
bol
ton in the parking brake toward the
housing.
SMT-890-1500 Ass'y-Draw t 1 Q
D 4 SMT-890-1540 Socket t 1 Q
Socket
7 790-302-1280 (Width across t 1
flats: 55 mm)
Disassembly 50-189
a When removing only the parking brake assem-
bly from the torque converter or the machine,
see "Removal and installation of parking brake 5) Remove the remaining ten mounting bolts to
assembly (installed on the machine)". remove parking brake assembly (13).
a Do not remove four hexagonal socket
1. Front coupling head bolts.
1) Using tool D7, remove the mounting bolt to a Use forcing screws to pull the parking
remove holder (1). brake assembly evenly out of the shaft
2) Remove coupling (2). end, and then sling and remove the as-
2. Cage sembly.
1) Remove six mounting bolts to remove cage a For procedures for disassembling the
(3) and shim (4). parking brake, see "Disassembly and as-
a Note the number and thickness of the sembly of parking brake".
shims for installation purpose. 5. Output shaft and gear assembly
2) Remove dust seal (5) from cage (3). 1) Remove eight mounting bolts to remove
3) Remove oil seal (6) from cage (3). cover (14).
3. Rear coupling 2) Remove output shaft and gear assembly
1) Using tool D7, remove the mounting bolt to (15).
remove holder (7). 3) Remove spacer (16) and gear (17) from shaft
2) Remove coupling (8). (18).
4. Parking brake assembly a Using a press, pull out the spacer and
1) Remove two mounting bolts to remove flange gear as a unit.
(9).
2) Remove sleeve (10).
a Screw an eyebolt (12 mm) into the sleeve
and pull out the sleeve.
3) Remove two plugs (11) and two pairs of bolts
and washers (12).
a You may remove any bolts and washers
because they are used for securing the
parking brake. However, you must not re-
move the four hexagonal socket head
bolts.
WA1200-6 50-189
Power train
6. Intermediate gear 8. Case

1) Remove two mounting bolts to remove plate 1) Remove the outer races of roller bearings
(19). (24) and (32) from case (33).
2) Remove 18 mounting bolts to remove cage a Use a bearing puller to pull out the race.
(20). 2) Remove taper roller bearing (34) from case
a Use forcing screws (12 mm) to pull out the (33).
cage. a Use a bearing puller to pull out the bear-
a Since the inner and outer races of the rolling.
er bearing are separated, pull out the
cage straight taking care not to pry the Assembly 50-190
races. a When installing only the parking brake assembly
3) Remove the outer race of roller bearing (21) to the torque converter or the machine, see "Re-
from cage (20). moval and installation of parking brake assembly
a Use a bearing puller to pull out the cage. (installed on the machine)".
4) Remove gear (22). 1. Case
a Since the inner and outer races of the roll- Install the outer races of roller bearings (24) and
er bearing are separated, pull out the (32) to case (33).
gear straight taking care not to pry the a Using a press, press fit the outer race until its
races. end face comes in contact with the stepped
5) Remove four mounting bolts to remove joint part of the case.
(23) from gear (22). 2. Input gear
6) Remove the inner races of roller bearings 1) Install the inner races of roller bearings (32)
(21) and (24) from gear (22). and (30) to gear (31).
a Use a bearing puller to pull out the race. a Using a press, press fit the inner race until
7. Input gear its end face comes in contact with the
1) Remove two mounting bolts to remove plate stepped part of the case.
(25). 2) Install gear (31).
2) Remove six mounting bolts to remove cage a Since the inner and outer races of the roll-
(26). er bearing are combined together, insert
a Since the inner and outer races of the roll- the gear straight taking care not to pry the
er bearing are separated, pull out the races.
cage straight taking care not to pry the 3) Install the outer race of roller bearing (30) to
races. cage (29).
3) Remove snap ring (27) and then remove joint a Using a press, press fit the outer race until
(28). its end face comes in contact with the
4) Remove 18 mounting bolts to remove cage stepped part of the cage.
(29). 4) Install cage (29) by using 18 bolts.
5) Remove the outer race of roller bearing (30) a Since the inner and outer races of the roll-
from cage (29). er bearing are combined together, insert
a Use a bearing puller to pull out the race. the cage straight taking care not to pry the
6) Remove gear (31). races.
a Since the inner and outer races of the roll- 5) Install joint (28) and secure it by using snap
er bearing are separated, pull out the ring (27).
gear straight taking care not to pry the 6) Install cage (26) with the O-ring by using six
races. bolts.
7) Remove the inner races of roller bearings 2 O-ring:
(30) and (32) from gear (31). Grease (G2-LI)
a Use a bearing puller to pull out the race. 7) Install plate (25) with the O-ring by using two
bolts.
50-190 WA1200-6
Power train
3. Intermediate gear 5. Parking brake assembly

1) Press fit the inner races of roller bearings 1) Set parking brake assembly (13) with the
(24) and (21) to gear (22). O-ring in the installation position, and then
a Using a press, press fit the inner race until tighten the ten bolts partially.
its end face comes in contact with the 2) Remove two pairs of bolts and washers (12)
stepped part of the gear. from parking brake assembly (13). Install
2) Install joint (23) to gear (22) by using four parking brake assembly (13) by using a total
bolts. of 12 bolts.
3) Install gear (22). a Loosen the two pairs of bolts and wash-
a Since the inner and outer races of the rollers slowly and alternately so that the pis-
er bearing are combined together, insert ton inside the parking brake is not pried.
the gear straight taking care not to pry the 2 Mounting bolt threaded section:
races. Adhesive (LT-2)
4) Install the outer race of roller bearing (21) to 3 Mounting bolt:
cage (20). 205.9 to 269.7 Nm {21.0 to 27.5
a Using a press, press fit the outer race until kgm}
5) Install cage (20) with the O-ring by using 18
bolts.
2 O-ring:
Grease (G2-LI)
a Since the inner and outer races of the roll-
er bearing are combined together, insert
the cage straight taking care not to pry the
races.
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
6) Install plate (19) with the O-ring by using two
bolts.
4. Output shaft and gear assembly
3) Install two plugs (11) to parking brake
1) Install tool D6 to case (33).
assembly (13).
4) Install sleeve (10) with the O-ring.
2 Sleeve:
Grease (G2-LI)
5) Install flange (9) with the O-ring by using two
bolts.
6) Remove tool D6.
7) Using tool D5, install taper roller bearing (34)
to case (33).
a The bearing consists of selectable combi-
nation parts. Handle the parts as a unit
when replacing the bearing.
a Press fit a bearing on each side. Be sure
to insert the centering.
2) Install gear (17) and spacer (16) to shaft (18).

a After installing the gear, use a press to
press fit the spacer until its end face
comes in contact with the stepped part of
the shaft.
3) Install output shaft and gear assembly (15).
4) Install cover (14) by using eight bolts.
WA1200-6 50-191
Power train
2) Select the thickness of shims to be used

according to the following procedure.
(1) Temporarily install cage (3) to case (33).
Measure installed dimension (a) between
the cage end face and the case end face.
a Do not fit shims.
(2) Remove cage (3) and measure cage
thickness (b).
(3) Calculate required thickness (c) of the
shim pack.
q c = (a - b) – (0.05 – 0.10)
a This is the dimension for pressing in
the bearing by 0.05 to 0.10 mm by us-
ing the cage.
6. Rear coupling a Standard thickness of shim pack (ref-
1) Install coupling (8). erence): 0.8 to 2.0 mm
a When the coupling cover was removed, a Available shims: 0.15 and 0.20 mm
install the cover by using tool D4.
a For tool D4, see the "Sketches of special
tools".
2) Install holder (7) by using tool D7 and bolts.
Adhesive (LT-2)
3 Mounting bolt:
2,059 to 2,354 Nm {210 to 240 kgm}
7. Cage
1) Use tool D2 to press fit oil seal (6) to cage (3).
the oil seal press fit surface on the cage.
After press fitting the oil seal, wipe off ex-
tra liquid gasket. 3) Fit shim (4) that is selected and install cage
a Press fit the oil seal until the flange of the (3) by using six bolts.
tool comes in contact with the cage. a The shim is 2-piece type. Be sure to in-
2 Oil seal lip: stall right and left shim packs of same
Grease (G2-LI) thickness.
4) Using tool D3, install dust seal (5) to cage (3).
a Press fit the dust seal until the flange of
the tool comes in contact with the cage.
2 Dust seal lip:
Grease (G2-LI)
50-192 WA1200-6
Power train
8. Front coupling
1) Install coupling (2).
2) Install holder (1) by using tool D7 and bolts.
Adhesive (LT-2)
3 Mounting bolt:
2,059 to 2,354 Nm {210 to 240 kgm}
WA1200-6 50-193
Power train
Disassembly and assembly of parking brake
Disassembly and assembly of parking brake 50-194
50-194 WA1200-6
Power train
Special tools 50-195 Assembly 50-195

1. Housing
New/redesign
Necessity
1) Using tool D2, install oil seal (20) to housing
Sketch
Sym-
Q'ty
Part No. Part name (19).
bol
the oil seal press fit surface on the hous-
SMT-890-1500 Ass'y-Draw t 1 Q ing. After press fitting the oil seal, wipe off
2 SMT-890-1510 q Socket t 1 Q extra liquid gasket.
D
SMT-890-1520 q Guide t 1 Q a Press fit the oil seal until the flange of the
3 SMT-890-1530 q Socket t 1 Q tool comes in contact with the housing.
2 Oil seal lip:
Grease (G2-LI)
Disassembly 50-195
1. Plate
Remove snap ring (1), then remove plate (2).
2. Plate and disc
Remove 17 plates (3), 16 discs (4), and 16
springs (5) alternately.
3. Drum 1
Remove drum (6).
4. Spacer
Remove spacer (7).
5. Drum 2
1) Remove two pairs of bolts and washers (8).
a They are the mounting bolts that were in-
stalled for removing the parking brake as-
sembly.
a Loosen the two pairs of bolts and wash- 2) Use tool D3 to press fit dust seal (18) to
ers slowly and alternately while checking housing (19).
that the piston moves toward the drum. a Press fit the dust seal until the flange of
2) Remove four mounting bolts to remove drum the tool comes in contact with the hous-
(9). ing.
2 Dust seal lip:
3) Remove snap ring (10) from drum (9).
6. Piston Grease (G2-LI)
1) Remove piston (11).
2) Remove seal rings (12) and (13) from piston
(11).
7. Spring
Remove springs (14) and (15), 14 pieces each.
8. Bearing
Remove snap ring (16), then remove bearing
(17).
9. Housing
1) Remove dust seal (18) from housing (19).
2) Remove oil seal (20) from housing (19).
2. Bearing
Install bearing (17) and secure it by using snap
ring (16).
a Using a press, press fit the bearing until its
end face comes in contact with the stepped
part of the housing.
3. Spring
Install springs (14) and (15), 14 pieces each.
4. Piston
1) Install seal rings (13) and (12) to piston (11).
WA1200-6 50-195
Power train
a The seal ring has its installed direction. 3) Screw two pairs of bolts and washers (8) into
Install the seal ring as shown in the draw- the plug holes in the housing.
ing below. a Use any two pairs of the parking brake
mounting bolts and washers. Do no re-
move them until the parking brake as-
sembly is installed to the transfer.
a Screw in the two pairs of bolts and wash-
ers slowly and alternately while checking
that the piston moves toward the housing.
2) Place piston (11) on the springs.

a Align the pin hole in the piston with the
dowel pin of the housing.
5. Drum 2
1) Install snap ring (10) to drum (9).
2) Place drum (9) on piston (11) and install the
drum by using four bolts. 6. Spacer
a Tighten the bolts evenly and slowly so Install spacer (7).
that the housing does not interfere with a The spacer also serves as an inner race of
the piston. the roller bearing. Insert it vertically so that it
is not pried.
7. Drum 2
Install drum (6).
8. Plate and disc
Remove 17 plates (3), 16 discs (4), and 16
springs (5) alternately.
9. Plate
Install plate (2) and secure it by using snap ring
(1).
50-196 WA1200-6
Power train
Removal and installation of parking brake assembly (installed on the machine)
Removal and installation of parking brake assembly (installed on the

machine) 50-197
WA1200-6 50-197
Power train
Preparation of tools 50-198 Removal 50-198
a Prepare tools used for removal and installation. 1. Remove the mounting bolt to remove holder (1).
[1] Shackle (2 pcs.) a When loosing the mounting bolt by using a
a Shackles not made to the specified dimen- torque multiplier wrench, hold the torque mul-
sions are unusable because they can cause tiplier wrench firmly by using a rope or band
interference. from above so that the joints between the
wrench and the bolt and between the wrench
and the torque multiplier are not disconnect-
ed.
2. Remove coupling (2).
3. Remove two mounting bolts to remove flange
(3).
4. Remove sleeve (4).
a Screw an eyebolt (12 mm) into the sleeve
and pull out the sleeve.
5. Remove two plugs (5) and two pairs of bolts and
washers (6).
a You may remove any bolts and washers be-
cause they are used for securing the parking
[2] Guide bolt (3 pcs.) brake. However, you must not remove the
four hexagonal socket head bolts.
6. Install the two pairs of removed bolts and
washers (6) into the plug holes.
a Tighten the two pairs of bolts and washers
slowly and alternately to move the piston in
the parking brake toward the housing.
50-198 WA1200-6
Power train
7. Remove the parking brake assembly according Installation 50-19

to the following procedure. 1. Install parking brake assembly (7) according to
1) Remove the remaining ten mounting bolts. the following procedure and tighten ten
a Do not remove four hexagonal socket mounting bolts partially.
head bolts. 1) Install shackles [1] in the positions shown in
2) Using forcing screws, pull out parking brake the drawing.
assembly (7) toward the rear of the machine 2) Sling parking brake assembly (7) from both
to a position where shackles [1] can be sides of the transmission and move the
installed. parking brake assembly to the transfer side
3) Install two shackles [1] in the positions shown until it connects completely to output shaft
in the drawing. (8).
4) Sling parking brake assembly (7) from both
sides of the transmission.
5) Move parking brake assembly (7) toward the
rear of the machine by using output shaft (8)
as a guide to remove the assembly.
3) Remove shackles [1] and install three guide

bolts [2] in the positions shown in the
drawing.
4) Push parking brake assembly (7) toward the
transfer to set it to the installed position.
5) Tighten ten bolts partially and remove guide
bolts [2].
WA1200-6 50-199
Power train
2. Remove two pairs of bolts and washers (6) from

parking brake assembly (7). Install parking brake
assembly (7) by using a total of 12 bolts.
a Loosen the bolts and washers slowly and al-
ternately so that the piston inside the parking
brake is not pried.
Adhesive (LT-2)
3 Mounting bolt:
205.9 to 269.7 Nm {21.0 to 27.5 kgm}
3. Install two plugs (5) to parking brake assembly

(7).
4. Install sleeve (4) with the O-ring.
2 Sleeve:
Grease (G2-LI)
5. Install flange (3) with the O-ring by using two
bolts.
6. Install coupling (2).
7. Install holder (1) by using the bolt.
a When tightening the mounting bolt by using a
torque multiplier wrench, hold the torque mul-
tiplier wrench firmly by using a rope or band
from above so that the joints between the
wrench and the bolt and between the wrench
and the torque multiplier are not disconnect-
ed.
Adhesive (LT-2)
2 Mounting bolt:
2,059 to 2,354 Nm {210 to 240 kgm}
50-200 WA1200-6
Power train
Removal and installation of transmission, brake cooling device and brake pump assembly
Removal and installation of transmission, brake cooling device and

brake pump assembly 50-201

ment "2. Preparatory work" and "3. Precau- q perform installation in the reverse order to the re-
tions during work" in "00 Safety notice". moval.
1. Drain the oil from the brake oil tank. [*1]

6 Brake oil tank: 3 Pump assembly mounting bolt:
approx. 315 l 98 to 123 Nm {10.0 to 12.5 kgm}
2. Open the upper step cover. q Flushing of brake circuit

If the pump is repaired for an internal damage,
3. Disconnect hoses (1), (2), (3), and (4). flush the brake circuit by referring to "Flushing
procedure for brake circuit".
q Refilling with oil (brake oil tank)

Refill the brake oil tank with hydraulic oil through
the oil filler port to the specified level.
q Refilling of oil (transmission)

Refill with oil to the specified level through the oil
filler port. Run the engine to circulate the oil
through the piping. Then, check the oil level
again.
q Air bleeding
Bleed air from the brake hydraulic circuit. For
details, see "Bleeding air from the brake
hydraulic circuit".
5. Disconnect tubes (7) and (8).
6. Sling pump assembly (9), remove mounting

bolts, and then remove the pump assembly. [*1]
4 Pump assembly:
75 kg
WA1200-6 50-201
Power train
Removal and installation of steering pump, control pump and PPC pump assembly
Removal and installation of steering pump, control pump and PPC pump
assembly 50-202

1. Drain the hydraulic oil. [*1]

6 Hydraulic oil: 3 Pump assembly mounting bolt:
approx. 1,125 l 455 to 565 Nm {46.5 to 58 kgm}
2. Open the upper step cover. q Flushing hydraulic circuit

If the pump is replaced for an internal damage,
3. Disconnect hoses (1) and (2). flush the hydraulic circuit by referring to
"Flushing procedure for work equipment and
4. Disconnect hoses (3), (4), (5) and (6). steering hydraulic circuit".
5. Remove clamp (7) and disconnect hose (8). q Refilling with oil (hydraulic tank)
Add oil through the oil filler to the specified level.
6. Disconnect hose (9). Run the engine to circulate the oil through the
q Air bleeding
8. Sling pump assembly (11), remove mounting Bleed air from the piston pump and work equip-
bolts, and then remove the pump assembly. [*1] ment hydraulic circuit. For details, see "Bleeding
4 Pump assembly: air from piston pump" and "Bleeding air from
250 kg work equipment hydraulic circuit and steering
hydraulic circuit".
50-202 WA1200-6
Power train
Disassembly and assembly of drive shaft
Disassembly and assembly of drive shaft 50-203
Disassembly 50-203 2. Center, front, and rear drive shafts

1. Upper drive shaft 1) Remove tube (23) from tube (24).
1) Remove cover (1) from yoke (2), then a Put matchmarks on tube (23) and tube
remove shaft (3). (24).
a Put matchmarks on yoke (2) and shaft a When replacing a tube, replace both
(3). tubes (23) and (24) at the same time.
2) Remove retainer (4), seal (5), and cover (1) 2) Remove seal (25) from tube (24).
from shaft (3). 3) Remove mounting bolts (26) from tubes (23)
3) Remove mounting bolts (6) from yoke (2) and and (24), then remove spider assembly (27).
shaft (3), then remove spider assembly (7). a Put matchmarks on the tubes and spider.
a Put matchmarks on the yoke, shaft, and * The drawing shows the center drive
spider. shaft.
WA1200-6 50-203
Power train
Disassembly and assembly of drive shaft
Assembly 50-204 2. Center, front, and rear drive shafts

1. Upper drive shaft 1) Install respective spider assemblies (27) to
1) Install respective spider assemblies (7) to tubes (23) and (24).
yoke (2) and shaft (3). a Wipe the bearing cap mounting face by
a Wipe the bearing cap mounting face by using a clean cloth.
using a clean cloth. a Align the matchmarks accurately.
a Align the matchmarks accurately. a The phase difference between the right
a The phase difference between the right and left spiders must be ± 3 degrees or
and left spiders must be ± 3 degrees or less.
less. 3 Mounting bolt:
3 Mounting bolt: 337 to 400 Nm {34.4 to 40.8 kgm}
206 to 221 Nm {21 to 22.5 kgm} 2) Install seal (25) to tube (24).
2) Install cover (1), two retainers (4), and seal 3) Align the matchmarks, then insert tube (23)
(5) to shaft (3). into tube (24).
3) Align the matchmarks, then insert shaft (3) a When inserting the tube, take care not to
into yoke (2) and secure them by using cover damage the seal.
(1). a If the spline is worn, replace the drive
a If the spline is worn, replace the drive shaft assembly.
shaft assembly. * The drawing shows the center drive
shaft.
50-204 WA1200-6
Power train
Removal and installation of front axle assembly
Removal and installation of front axle assembly 50-205
Special tools 50-205 5. Sling and remove front drive shaft (3).
[*2]
New/redesign
a Before the removal, put a matchmark on the
Necessity
Sketch
Sym-
Q'ty
Part No. Part name drive shaft coupling to indicate its installed
bol
position.
4 Front drive shaft:
1 793T-870-1410 stand q 1 Q 280 kg
L
4 SMT-890-5020 Plate q 1 Q
Removal 50-205
1. Place a steel plate on the ground under the front
axle.
2. Start the engine. Raise the machine off the
ground by using the work equipment and set
stand L1 at the bottom of the front frame.
a Set steel plate [1] between the stand and the
ground.
a Chock the rear wheels.
3. Remove right and left fenders (1). 6. Drain the oil from the brake tank.
6 Brake oil:
4. Sling tire (2) and remove the mounting nuts to
remove the right and left tires. [*1] approx. 45 l
4 Tire (per tire):
7. Disconnect brake hoses (4), (5) and (6).
9,150 kg
WA1200-6 50-205
Power train
Removal and installation of front axle assembly
8. Sling front axle assembly (7), remove 16 Installation 50-206

mounting bolts (8), and lower the front axle q Perform installation in the reverse order to re-
assembly onto the steel plate. [*3] moval.
a If the nut turns together with the mounting [*1]
bolt, use tool L4 (plate). 3 Tire mounting nut:
9. Using a crane or other equipment, pull out the 1,470 to 1,810 Nm {150 to 185 kgm}
front axle assembly to the outside. [*2]
4 Front axle assembly: 3 Drive shaft mounting bolt:
16,500 kg 343 to 427 Nm {35 to 43.5 kgm}
[*3]
q If the nut turns together with the mounting bolt,
use tool L4 (plate).
3 Axle assembly mounting nut:
4,510 to 5,490 Nm {460 to 560 kgm}
q Refilling with oil (brake tank)

Add oil to the specified level through the oil filler
port.
5 Brake oil:
approx. 45 l
q Air bleeding
Bleed the air in the wheel brake circuit. For
details, see "Bleeding air from brake circuit".
After completion of the air bleeding operation,
add hydraulic oil to the brake tank to the speci-
fied level.
50-206 WA1200-6
Power train
Removal and installation of front final drive assembly
Removal and installation of front final drive assembly 50-207
Special tools 50-207 5. Drain the oil from the brake tank.
6 Brake oil:
New/redesign
approx. 45 l
Necessity
Sketch
Sym-
Q'ty
Part No. Part name 6. Disconnect brake hoses (4), (5) and (6).
bol
1 793T-870-1410 stand q 1 Q
L
4 SMT-890-5020 Plate q 1 Q
SMT-890-5100 Handle assembly t 1 Q
SMT-890-5120 q Flange t 1 Q
q Hexagon
J 4 01252-61675 socket head t 2
bolt
q Hexagon
01252-62045 socket head t 1
bolt
01580-31613 q Nut t 1
7. Remove drain plugs (8) of the right and left final
cases and drain plug (9) of the differential case
Removal 50-207 to drain oil. [*2]
k Before performing removal, be sure to imple- a Take care that the amount of oil to drain is
ment "2. Preparatory work" and "3. Precau- large and the oil spurts out while draining.
tions during work" in "00 Safety notice". 6 Axle oil:
1. Place a steel plate on the ground under the front 670 l
axle.
2. Start the engine. Raise the machine off the
ground by using the work equipment and set
stand L1 at the bottom of the front frame.
a Set steel plate [1] between the stand and the
ground.
a Chock the rear wheels.
3. Remove right and left fenders (1).
4. Sling tire (2) and remove the mounting nuts to
remove the right and left tires. [*1]
4 Tire (per tire):
9,150 kg
WA1200-6 50-207
Power train
Removal and installation of front final drive assembly
8. Remove final case cover (10). [*3] Installation 50-208

9. Remove sun gear (11). Perform installation in the reverse order to removal.
10. Sling axle shaft assembly (12) and pull the [*1]
assembly out of the spline portion of the differen- 3 Tire mounting nut:
tial. [*4] 1,470 to 1,810 Nm {150 to 185 kgm}
a Pull out the shaft assembly on the opposite [*2]
side in the same way. 3 Drain plug (8):
127 to 176 Nm {13 to 18 kgm}
3 Drain plug (9):
127 to 176 Nm {13 to 18 kgm}
[*3]
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
[*4]
Use tool J4 to insert the axle shaft assembly.
[*5]
3 Final drive assembly mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}

port.
5 Brake oil:
11. Wrap nylon sling [3] around the final drive
assembly. [*4, 5]
4 Final drive assembly:
approx. 45 l
5,000 kg
q Refilling with oil (axle and final drive)
port.
5 Axle oil:
670 l (AXO80)
q Air bleeding
fied level.
50-208 WA1200-6
Power train
Removal and installation of rear axle assembly
Removal and installation of rear axle assembly 50-209
Special tools 50-209 a Use liner plates to adjust the height from
the steel plate to the frame to the follow-
New/redesign
Necessity
ing values.
Sketch
Sym-
Q'ty
Part No. Part name A = 877 mm, B = 1,527 mm
bol
2. Remove the step cover above the left tire.
3 793T-870-1420 stand q 1 Q 3. Sling tire (1) and remove the mounting nuts to
4 793T-870-1430 stand q 1 Q remove the right and left tires. [*1]
4 Tire (per tire):
L
5 SMT-890-5030 Plate q 1 Q
6 SMT-890-5040 Plate q 1 Q 9,150 kg
SMT-890-5100 Handle assembly t 1 Q [1] and [2]: Steel plates
q Hexagon
J 4 01252-61675 socket head t 2
bolt
q Hexagon
bolt
01580-31613 q Nut t 1
Removal 50-209
during work" in "00 Safety notice". 4. Drain the oil from the brake tank.
1. Secure the space for pulling out the rear axle 6 Brake oil:
assembly at either side of the machine, and set approx. 45 l
steel plates and stands according to the 5. Sling and remove rear drive shaft (2).
following procedure. [*2]
1) Place steel plates without gap on the ground a Before the removal, put a matchmark on the
below the rear axle assembly on the ground rear drive shaft coupling to indicate its in-
where the removed rear axle assembly is to stalled position.
be placed. 4 Rear drive shaft:
2) Place the machine according to the positions 290 kg
where the stands are to be set.
3) Set strands L3 and L4 and lower the machine

slowly.
4 Weight of rear end of machine:
67,200 kg
WA1200-6 50-209
Power train
6. Disconnect grease hoses (3) and (4) of the axle (Rollers are attached to the bottom of the truck.)
support.
(Install the trucks to the right and left ends at the

7. Disconnect brake hoses (5), (6) and (7). bottom of the rear axle.) Fix the trucks to the axle
so that the rollers of the right and left trucks are
set horizontally.
8. Use axle sling [4] to sling the rear axle assembly.

a The removed rear axle assembly can be
moved safety and effectively if trucks [3] with
rollers are made on the site and installed to
the bottom of the rear axle assembly.
(The following shows an example.)
(Prepare two trucks to support right and left ends
of the axle.)
50-210 WA1200-6
Power train
11. Remove remaining four mounting nuts (9), and

lower rear axle assembly (8).
4 Rear axle assembly:
16,600 kg
9. Loosen 18 mounting nuts (9) of the front and rear

axle supports, leave one nut at each of the right
and left side, and remove remaining nuts. [*3]
a If the mounting bolt turns together, use tools
L5 and L6 (plate) to lock the bolt head.
10. Use nylon sling or chain to fix the front and rear
axle supports to rear axle (8).
k For the safety purpose, loosen the center
bolt but leave it in the position.
WA1200-6 50-211
Power train
Installation 50-212 2) Apply instantaneous adhesive to the bushing

q When replacing the axle support bushing, install mounting face.
according to the following procedure. 2 Bushing mounting face:
1. Place rear axle (8) on a flat strand. Liquid instantaneous adhesive
(LOCTITE 499) Approx. 5 g
Hardening accelerator (LOCTITE
712)
2. Front support
1) Degrease the bushing and support mounting
faces.
a When removing anti-rust oil, do not use (Application example)
metallic objects like scraper on the sup-
port mounting face.
(Bad example of using scraper)
50-212 WA1200-6
Power train
3) Install bushings (11) to the front support. 4) Install dust seal (12) to retainer (14), and
a Bend the bushing inward and install it so install retainer (14) to the front side of front
that the entire outer periphery of the support (10a).
bushing contacts with the inner face of a Install the retainer with the dust seal lip
the support securely according to the facing outside.
drawing below.
5) Install dust seal (13) to the rear side of front
support (10a).
WA1200-6 50-213
Power train
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
a When reusing the mounting bolt, apply
seizure prevention compound to the
threaded portion.
2 Mounting bolt:
Seizure prevention compound
(LC-G)
50-214 WA1200-6
Power train
a Install the dust seal the lip facing outside.
6) Apply grease to the entire inner periphery of 8) Sling front support assembly (10a) to install
bushing (11) and dust seals (12) and (13). to rear axle assembly (8).
2 Bushing and dust seal: 4 Front support assembly:
Molybdenum disulphied grease 650 kg
(LM-G)
a Insert the front support assembly while

7) Apply grease to the outer periphery of the wobbling its right end.
front support mounting face on the rear axle.
2 Outer periphery of the front sup-
port mounting face:
Molybdenum disulphied grease
(LM-G)
WA1200-6 50-215
Power train
9) Pump grease through grease fitting portion 3. Rear support

[GF] at the top of the front support assembly. 1) Install bushings (11) and dust seals (13) to
a When inserting the front support assem- rear support (10b) according to the same
bly, check that a sufficient amount of procedure as to front support (10a).
grease flows out of the gap between the
inner periphery of the front support as-
sembly and the rear axle portion.
a Pump grease until it flows out as shown in

the drawing below.
50-216 WA1200-6
Power train
a Install the dust seal with the lip facing outside.
2) Apply grease to the entire inner periphery of 4) Sling rear support assembly (10b) to install to
bushings (11) and dust seal (13). rear axle assembly (8).
2 Bushing and dust seal: a Insert the rear support assembly while
Molybdenum disulphied grease wobbling its right end vertically.
(LM-G) 4 Rear support assembly:
960 kg
3) Apply grease to the outer periphery of the

rear support mounting face on the rear axle. 5) Set thrust washer (16) to the inside of thrust
2 Outer periphery of rear support plate (15), and install them to rear axle (8).
mounting face: 4 Thrust plate:
Molybdenum disulphied grease 100 kg
(LM-G) 3 Mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}
WA1200-6 50-217
Power train
a When reusing the mounting bolt, apply 7) Set the thrust washer to the rear support
seizure prevention compound to the assembly.
threaded portion. 4 Thrust washer:
2 Mounting bolt: 100 kg
Seizure prevention compound 8) Install cover (18) to rear support assembly
(LC-G) (10b).
4 Rear cover:
160 kg
3 Mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}
a When reusing the mounting bolt, apply
seizure prevention compound to the
threaded portion.
2 Mounting bolt:
Seizure prevention compound
(LC-G)
6) Apply grease to thrust washer (17) contact

face (A) on thrust plate (15) and thrust
washer (17) contact face (B) on rear cover
(18).
2 Thrust plate and rear cover faces:
Molybdenum disulphied grease
(LM-G)
50-218 WA1200-6
Power train
9) Pump grease through the rear breather q Perform the subsequent installation in the re-
mounting hole. verse order to removal.
Pump grease through the grease filling [*1]
nipple mounting hole (D) at the top of the rear 3 Tire mounting nut:
support. 1,470 to 1,810 Nm {150 to 185 kgm}
a Pump grease until it flows out from the [*2]
grease filling nipple mounting hole (P) at 3 Drive shaft mounting bolt:
the top of the rear support and dust seal 343 to 427 Nm {35 to 43.5 kgm}
portion (Q). [*3]
q Use tools L5 and L6 (plate) to prevent the nut
from turning together with the mounting bolt.
3 Support mounting nut:
4,510 to 5,490 Nm {460 to 560 kgm}

port.
5 Brake oil:
approx. 45 l
q Air bleeding
fied level.
WA1200-6 50-219
Power train
Removal and installation of rear final drive assembly
Removal and installation of rear final drive assembly 50-2 0
Special tools 50-2 0 2. Drain the oil from the brake tank.
6 Brake oil:
New/redesign
approx. 45 l
Necessity
Sketch
Sym-
Q'ty
Part No. Part name 3. Sling tire (1) of the final drive to be removed.
bol
4. Remove the mounting nuts to remove the right or
3 793T-870-1420 stand t 1 Q left tire.
L
4 793T-870-1430 stand t 1 Q [*1]
SMT-890-5100 Handle assembly t 1 Q 4 Tire (per tire):
SMT-890-5110 q Handle t 1 Q 9,150 kg

SMT-890-5120 q Flange t 1 Q 5. Disconnect brake hoses (5), (6) and (7).
q Hexagon
J 4 01252-61675 socket head t 2
bolt
q Hexagon
bolt
01580-31613 q Nut t 1
Removal 50-2 0
1. If the ground is soft, place steel plates and

stands according to the following procedure.
1) Place steel plates [1] and [2] on the ground
2) Place the machine according to the positions
3) Set strands L3 and L4 and lower the machine
slowly.
4 Weight of rear end of machine:
67,200 kg
a Use liner plates to adjust the height from the
steel plate to the frame to the following val-
ues.
A = 887 mm, B = 1,527 mm
50-220 WA1200-6
Power train
6. Remove drain plugs (8) of the right and left final 7. Remove final case cover (10). [*3]
to drain oil. [*2] 8. Remove sun gear (11).
a Take care that the amount of oil to drain is
large and the oil spurts out while draining. 9. Sling axle shaft assembly (12) and pull the
6 Axle oil: assembly out of the spline portion of the differen-
670 l tial. [*4]
a Pull out the shaft assembly on the opposite
side in the same way.
10. Wrap nylon sling [3] around the final drive

assembly.
11. Remove the 36 mounting bolts to remove the

final drive assembly. [*5]
4 Final drive assembly:
5,500 kg
WA1200-6 50-221
Power train
Installation 50-2 2
a Do not reuse kit parts shown in the installation
procedure, but replace with new ones.
q Perform installation in the reverse order to re-
moval.
[*1]
3 Tire mounting nut:
1,470 to 1,810 Nm {150 to 185 kgm}
[*2]
3 Drain plug (8):
127 to 176 Nm {13 to 18 kgm}
3 Drain plug (9):
127 to 176 Nm {13 to 18 kgm}
[*3]
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
[*4]
[*5]
3 Final drive assembly mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}

port.
5 Brake oil:
approx. 45 l
q Refilling with oil (axle and final drive)
port.
5 Axle oil:
670 l (AXO80)
q Air bleeding
fied level.
50-222 WA1200-6
Power train
Removal and installation of differential assembly
Removal and installation of differential assembly 50-2 3
Special tools 50-2 3 2. Remove drain plugs (2) of the right and left final
New/redesign
Necessity
to drain oil. [*1]
Sketch
Sym-
a Take care that the amount of oil to drain is
Q'ty
Part No. Part name
bol
large and the oil spurts out while draining.
6 Axle oil:
SMT-890-5100 Handle assembly t 1 Q 670 l
q Hexagon
J 4 01252-61675 socket head t 2
bolt
q Hexagon
bolt
01580-31613 q Nut t 1
Removal 50-2 3
1. Remove axle assembly (1) and set it on wooden
blocks [1]. For details, see "Removal and instal-
lation of front axle assembly" or "Removal and
installation of rear axle assembly".
4 Front axle assembly:
16,500 kg
4 Rear axle assembly:
16,600 kg
3. Remove final case cover (4). [*2]

4. Remove sun gear (5).
5. Sling axle shaft assembly (6) and pull the
assembly out of the spline portion of the differen-
tial. [*3]
a Pull out the shaft assembly on the opposite
side in the same way.
WA1200-6 50-223
Power train
Removal and installation of differential assembly
Installation 50-2 4
6. Remove speed sensor (7). [*4] q Perform installation in the reverse order to re-
a Front axle only moval.
[*1]
7. Remove mounting bolts (8) and remove differen- 3 Drain plug (2):
tial assembly (9). [*5] 127 to 176 Nm {13 to 18 kgm}
a Mounting bolt of different dimensions are 3 Drain plug (3):
used. Note the installed positions of bolts. 127 to 176 Nm {13 to 18 kgm}
[*2]
3 Mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}
[*3]
[*4]
Front axle only
1. Insert the speed sensor until its tip comes into
contact with the flange.
2. Measure the clearance between the speed
sensor flange and the housing mounting face.
3. Adjust the clearance with shims so that the
formula of Shim pack thickness = (clearance) +
(0.7 ± 0.1 mm) holds.
a Clearance at sensor tip: 0.7 ± 0.1 mm
3 Sensor mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
[*5]
3 Mounting bolt:
1,520 to 1,910 Nm {155 to 195 kgm}
50-224 WA1200-6
Power train
Disassembly and assembly of differential
Disassembly and assembly of differential 50-2 5
Front differential 50-2 5
WA1200-6 50-225
Power train
Rear differential 50-2 6
50-226 WA1200-6
Power train
Special tools 50-2 7 7) Remove dust seal (20) from cage (19).
8) Remove oil seal (21) from cage (19).
New/redesign
Necessity
9) Using a press, remove pinion (22) and the
Sketch
Sym-
Q'ty
Part No. Part name inner race of bearing (24) as a unit from cage
bol
(15).
10)Remove the inner race of roller bearing (23)
792-340-1120 Nut wrench t 1 from cage (15).
1
796-550-1310 Wrench t 1 11)Remove the inner race of roller bearing (24)
J 792-525-3000 Micrometer t 1 from pinion (22).
2 790-425-1670 Adapter t 1
790-425-1660 Wrench t 1
12)Remove the outer races of roller bearings
(23) and (24) from cage (15).
Disassembly 50-2 7 a Use a bearing puller to pull out.
1. Cover
Remove two mounting bolts to remove cover (8). Rear differential
a Front differential only 1) Remove 24 mounting bolts to remove cage
assembly (13).
2. Flange 2) Remove shim (14) from cage (15).
Remove snap ring (9), then remove flange (10). a Note the number and thickness of the
a Front differential only shims for installation purpose.
3) Remove the mounting bolts, then remove
3. Lock plate holder (16) and shim (17).
Remove four mounting bolts, and remove two a Note the number and thickness of the
lock plates (11). shims for installation purpose.
a After removing the lock plate, mark the lock 4) Remove coupling (18).
position on the adjustment nut (26). 5) Remove eight mounting bolts to remove
support (15A).
4. Cage assembly 6) Remove four mounting bolts to remove cage
Front differential (19).
1) Remove two mounting bolts and bracket 7) Remove dust seal (20) from cage (19).
(12). 8) Remove oil seal (21) from cage (19).
2) Remove 22 mounting bolts and cage 9) Using a press, remove pinion (22) and the
assembly (13). inner race of bearing (24) as a unit from cage
3) Remove shim (14) from cage (15). (15).
a Note the number and thickness of the 10)Remove the inner race of roller bearing (23)
shims for installation purpose. from cage (15).
4) Remove the mounting bolts, then remove 11)Remove the inner race of roller bearing (24)
holder (16) and shim (17). from pinion (22).
a Note the number and thickness of the a Use a press to pull out.
shims for installation purpose. 12)Remove the outer races of roller bearings
5) Remove coupling (18). (23) and (24) from cage (15).
6) Remove four mounting bolts to remove cage a Use a bearing puller to pull out.
(19).
WA1200-6 50-227
Power train
5. Differential gear assembly 5] Using a press, remove outer race (38D)

1) Remove four mounting bolts, and remove from pinion gear (36).
two caps (25). 6] Using a press, remove collar (38E) and
a Separate the right and left caps. outer race (38F) from pinion gear (36).
2) Remove two nuts (26).
3) Remove differential gear assembly (28) and
two outer races of bearing (27) from carrier
(29).
a Take care not to drop the bearing when
lifting the differential gear assembly.
a Separate the right and left bearings.
4) Remove eight mounting bolts to remove case
(30).
a Make matchmarks on the case before re-
moving.
5) Remove the inner race of bearing (27) and
thrust washer (31) from case (30).
6) Remove side gear (32), and remove spider
shaft (33) and pinion gear assembly (34) as 9) Remove side gear (39).
a unit. 10)Remove the inner race of bearing (27) and
7) Remove four pinion gear assembly (34) from thrust washer (40) from case (41).
spider shaft (33). 11)Remove tube (42) and remove two bushings
8) Disassemble pinion gear assembly (34) (43).
according to the following procedure. a Front differential only
1] Secure pinion gear assembly (34) with a 12)Remove 20 bolts to remove bevel gear (44).
press, and remove lock nut (35) with a Make matchmarks on the bevel gear and
wrench J1. case before removing.
2] Using a press, remove sleeve (37) from
pinion gear (36).
3] Remove inner race (38A) from pinion
gear (36).
4] Remove spacer (38B) and inner race
(38C) from sleeve (37).
50-228 WA1200-6
Power train
Assembly 50-2 9
1. Differential gear assembly
1) Apply LOCTITE 648 on the back side of the
bevel gear as shown in the drawing, and
install bevel gear (44) to case (41) with 20
bolts.
a Match the matchmarks on the bevel gear
and the case.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
a Apply 2 to 3 mm wide loctite 648 around
the screw hole shown in the following fig-
ure. 3] Install spacer (38B) and inner race (38C)
to sleeve (37).
4] Install sleeve (37) to pinion gear (36).
5] Install inner race (38A) to pinion gear
(36).
6] Secure pinion gear assembly (34) with a
press, and tighten nut (35) with wrench
J1.
3 Nut:
882 to 1,080 Nm {90 to 110 kgm}
2) Install two bushings (43) to case (41).

a Front differential only
3) Install tube (42) to case (41).
a Front differential only
4) Install the inner race of bearing (27) and
thrust washer (40) to case (41).
2 Contact surfaces on thrust washer
(40) and side gear (39):
Axle oil (AXO80)
5) Install side gear (39) to case (41). 7) Install spider shaft (33) with four pinion gear
6) Assemble pinion gear (34) according to the assemblies (34) to case (41).
following procedure. 8) Install side gear (32).
1] Using a press, install collar (38E) and a Move the side gear to check that the pin-
outer race (38F) to pinion gear (36). ion gears rotate smoothly.
a Press fit the outer race until its end
face comes in contact with the pinion
gear.
2] Using a press, install outer race (38D) to
pinion gear (36).
a Press fit the outer race until its end
face comes in contact with the pinion
gear.
WA1200-6 50-229
Power train
9) Install the inner race of bearing (27) and 14)Install two caps (25) to carrier (29) with four
thrust washer (31) to case (30). bolts.
a When installing the right and left bear- a Check that right and left caps are on the
ings, check the identification mark put on correct sides.
the right and left inner races to prevent a Tighten the bolts after rotating the bevel
wrong installation. gear 20 to 30 turns to run in the bearing.
2 Contact surfaces on thrust washer 3 Mounting bolt:
(31) and side gear (32): 1,520 to 1,910 Nm {155 to 195 kgm}
Axle oil (AXO80)
10)Install case (30) to case (41) with eight bolts.
a Align the matchmarks on the cases.
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
11)Install two outer races of bearings (27) to
cases (41) and (30).
a When installing the right and left bear-
ings, check the identification mark put on
the right and left outer races to prevent
wrong installation.
12)Install differential gear assembly (28) to
carrier (29).
15)Adjust the preload of the differential side

bearing according to the following procedure.
1] Install tools J2(adapter)to the threaded
portions a (2 pieces) of cap (25).
a Tighten so that it is not rattle.
2] Before adjustment, use tool J2 (microm-
eter) to measure dimension L between
the tool J2 (adapter) outer ends (at 14
mm from the top of the cap).
3] Using tool J2 (wrench), tighten nut (26)
and measure dimension L.
Adjust the tightening amount of nut (26)
so that the increment value of L is within
13)Tighten two nuts (26) to carrier (29) partially. the standard range. Also, rotate bearing
a Check that the carrier rotates smoothly by (27) until the full contact of the bearing
hand. with the surrounding portion is ensured.
4] Check that the torque of bevel gear (44)
at its outer diameter is within the standard
range.
a Standard value of increment value of
L (cap opening amount):
0.35 to 0.60 mm
a Torque of bevel gear (44) (tangential
force at outside diameter of 843 mm)
(reference): 34.3 to 73.5 N {3.5 to 7.5
kg}
50-230 WA1200-6
Power train
a Precautions when adjusting preload 2. Cage assembly

If the deflection should exceed the Front differential
standard dimension due to overtight- 1) Install the outer races of roller bearings (23)
ening of the adjustment nut, return the and (24) to cage (15).
nut to the position before the adjust- a Press fit the outer race until its end face
ment. To do this, lightly hit the bearing comes in contact with the stepped part of
cap and bevel gear with a plastic the cage.
hammer, etc. while rotating the bevel 2) Install the inner race of roller bearing (24) to
gear. Make sure that no clearance pinion (22).
exists in the nut and bearing portions a Press fit the inner race until its end face
and then make adjustment again. comes in contact with the pinion.
3) Install pinion (22) to cage (15).
2 Bearing:
Axle oil (AXO80)
a Press fit the bearing while turning the
cage, and stop press fitting when a load is
applied.
a Press fit with the minimum load required
to push in the bearing.
4) Install the inner race of roller bearing (23) to
pinion (22).
5) Adjust the shim pack thickness of the input
bearing according to the following procedure.
1] Measure thickness "a" of the holder.
2] Install coupling (18) to pinion (22) and
temporary install holder (16) with the bolt.
a Do not fit shims.
3] While rotating the bearing to fit in, tighten
the bolt gradually until the starting torque
of 15.7 Nm {1.6 kgm} is obtained.
4] Measure dimension "b" from the holder to
the pinion end face.
5] Calculate necessary shim pack thickness
"c".
q c = (b - a) - (0 – 0.04) mm
a Select shims so that the shim pack
thickness is -0 to -0.04 mm from the
clearance.
a Available shims: 0.05, 0.2, 0.3, and
1.0 mm
a Obtain the necessary thickness by us-
ing a minimum number of shims.
6] Install the selected shims and tighten with
bolts.
a Be sure to install washer (45).
7] Rotate cage (15) to fit in the bearing, and
check that the staring torque is within the
range of 15.7 to 52.0 Nm {1.6 to 5.3 kgm}.
a If it is outside the range, adjust the
shims again.
WA1200-6 50-231
Power train
9) Install cage (19) to cage (15) with four bolts.

3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}
10)Install coupling (18) to pinion (22), and install
the O-ring.
2 Yoke end face and shaft spline:
Lubricant (LM-G)
11)Fit the selected shims, and install holder (16)
and washer (45) with the bolt.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}
6) Install the O-ring to cage (19).

7) Install oil seal (21) to cage (19).
8) Install dust seal (20) to cage (19).
a Dust seal press fit dimension "c": 4 mm
from cage end face
2 Oil seal press fit portion:
Liquid gasket (LG-1 or LG-5)
2 Seal lip:
Grease (G2-LI)
12)Install the O-ring to cage (15).

13)Adjust the shim pack thickness of the differ-
ential carrier according to the following
procedure.
a If the bearing, pinion gear, bevel gear,
etc. is replaced, perform the shim adjust-
ment procedure.
1] Measure distance "a" from carrier (29) to
pinion gear (22).
50-232 WA1200-6
Power train
2] Calculate reference value "b". Rear differential

q b = (427 + c) - (121.69 + d) mm 1) Install the outer races of roller bearings (23)
a Dimension "c" and dimension "d" are and (24) to cage (15).
indicated at the tip of the pinion shaft a Press fit the outer race until its end face
in icrements of 1/100 mm. comes in contact with the stepped part of
(Be careful with the plus and minus the cage.
signs.) 2) Install the inner race of roller bearing (24) to
pinion (22).
a Press fit the inner race until its end face
comes in contact with the pinion.

"e".
q e = b- a
a Available shims: 0.2, 0.3, and 1.0 mm 3) Install pinion (22) to cage (15).
a Obtain the necessary thickness by us- 2 Bearing:
ing a minimum number of shims. Axle oil (AXO80)
14)Fit selected shims (14), and install cage (15) a Press fit the bearing while turning the
to cage (29) with 22 bolts. cage, and stop press fitting when a load is
3 Mounting bolt: applied.
1,520 to 1,910 Nm {155 to 195 kgm} a Press fit with the minimum load required
15)Install bracket (12) to cage (15) with two to push in the bearing.
bolts.
3 Mounting bolt:
1,520 to 1,910 Nm {155 to 195 kgm}
WA1200-6 50-233
Power train
4) Install the inner race of roller bearing (23) to a If it is outside the range, adjust the
pinion (22). shims again.
5) Adjust the shim pack thickness of the input 6) Install the O-ring to cage (19).
bearing according to the following procedure. 7) Install oil seal (21) to cage (19).
1] Measure thickness "a" of the holder. 8) Install dust seal (20) to cage (19).
2] Install coupling (18) to pinion (22) and a Dust seal press fit dimension "c": 4 mm
temporary install holder (16) with the bolt. from cage end face
a Do not fit shims. 2 Oil seal press fit portion:
Liquid gasket (LG-1 or LG-5)
2 Seal lip:
Grease (G2-LI)
3] While rotating the bearing to fit in, tighten

the bolt gradually until the starting torque
of 15.7 Nm {1.6 kgm} is obtained.
4] Measure dimension "b" from the holder to
the pinion end face.
"c".
q c = (b - a) - (0 – 0.04) mm
a Select shims so that the shim pack
thickness is -0 to -0.04 mm from the
clearance.
a Available shims: 0.05, 0.2, 0.3, and
1.0 mm
6] Install the selected shims and tighten with
bolts.
a Be sure to install washer (45).
7] Rotate cage (15) to fit in the bearing, and
check that the staring torque is within the
range of 15.7 to 52.0 Nm {1.6 to 5.3 kgm}.
50-234 WA1200-6
Power train
9) Install cage (19) to cage (15) with four bolts. 13)Install the O-ring to cage (15).
3 Mounting bolt: 14)Adjust the shim pack thickness of the differ-
157 to 196 Nm {16 to 20 kgm} ential carrier according to the following
procedure.
a If the bearing, pinion gear, bevel gear,
etc. is replaced, perform the shim adjust-
ment procedure.
1] Measure distance "a" from carrier (29) to
pinion gear (22).
10)Install support (15A).

3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
11)Install coupling (18) to pinion (22), and install
the O-ring.
2 Yoke end face and shaft spline:
Lubricant (LM-G) 2] Calculate reference value "b".
12)Fit the selected shims, and install holder (16) q b =(427 + c) - (121.69 + d) mm
and washer (45) with the bolt. a Dimension "c" and dimension "d" are
2 Mounting bolt: indicated at the tip of the pinion shaft
Adhesive (LT-2) in increments of 1/100 mm.
3 Mounting bolt: (Be careful with the plus and minus
2,450 to 3,040 Nm {250 to 310 kgm} signs.)

"e".
q e =b - a
a Available shims: 0.2, 0.3, and 1.0 mm
WA1200-6 50-235
Power train
15)Fit selected shims (14), and install cage (15) 1) If proper tooth contact pattern is not obtained
to cage (29) with 24 bolts. upon checking, perform tooth contact adjust-
3 Mounting bolt: ment.
1,520 to 1,910 Nm {155 to 195 kgm} a Tooth contact adjustment is performed by
moving the bevel gear and increasing or
3. Adjust the bevel pinion backlash according to decreasing the shims of the cage assem-
the following procedure. bly (to move the bevel pinion).
a Use the adjustment nuts to move the bevel a After adjusting the tooth contact, check
gear. the backlash again.
Turn the nuts on both sides by the same a When adjusting the bevel gear position to
angle in the same direction so that the the right or left, turn both right and left ad-
preload of the bearing does not change. justment nuts to the same direction by the
1] Attach dial gauge J2 to the outer end of same amount (check by the shifting of the
the bevel gear. notch) so that the preload of the bearing
2] Adjust the backlash with the adjustment is not changed.
nuts so that the backlash is within the a Available shims: 0.2, 0.3, and 1.0 mm
specified range. 2) If the bevel pinion is too far from the bevel
a Backlash: 0.43 to 0.61 mm gear, the tooth contact pattern is as shown in
a Measure the backlash at three to four the following figure. Make a correction
places with the pinion gear locked. according to the following procedure.
q Decrease the shims of the cage assembly
4. Coat the bevel gear tooth surface slightly with (on the bevel pinion side) to move the
red lead, then check the tooth contact. bevel pinion in the direction of C.
a Turn the bevel gear, and check that the con- q Adjust the bearing adjustment nut to
tact pattern on the concave and convex sur- move the bevel gear in the direction of D
faces are within the range specified in the away from the bevel pinion.
drawing below.
50-236 WA1200-6
Power train
3) If the bevel pinion is too close to the bevel 5) If the bevel gear is too far from the bevel
gear, the tooth contact pattern is as shown in pinion, the toorh contact pattern is as shown
the following figure. Make a correction in the following figure. Make correction
according to the following procedure. according to the following procedure:
q Increase the shims of the cage assembly q Increase the shims of the cage assembly
(on the bevel pinion side) to move the (on the bevel pinion side) to move the
bevel pinion in the direction of E. bevel pinion in the direction of E.
q Adjust the bearing adjustment nut to q Adjust the bearing adjustment nut to
move the bevel gear in the direction of F move the bevel gear in the direction of F
closer to the bevel pinion. closer to the bevel pinion.
4) If the bevel gear is too close to the bevel 5. Lock plate

pinion, the tooth contact pattern is as shown Install two lock plates (11) with four bolts.
in the following figure. Make correction 3 Mounting bolt:
according to the following procedure. 245 to 309 Nm {25 to 31.5 kgm}
q Decrease the shims of the cage assembly 6. Flange
(on the bevel pinion side) to move the Install flange (10) and install snap ring (9).
bevel pinion in the direction of C. a Front differential only
q Adjust the bearing adjustment nut to 7. Cover
move the bevel gear in the direction of D Install cover (8) with two bolts.
away from the bevel pinion. a Front differential only
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
2 Mounting bolt:
Adhesive (LT2)
WA1200-6 50-237
Power train
Disassembly and assembly of final drive and brake
Disassembly and assembly of final drive and brake 50-238
50-238 WA1200-6
Power train
WA1200-6 50-239
Power train
Special tools 50-240 6. Carrier assembly (small)

1) Remove carrier assembly (22).
New/redesign
Necessity
2) Remove spacer (24) from carrier (23).
Sketch
Sym-
Q'ty
Part No. Part name 3) Remove snap ring (25), then remove pin
bol
(26).
a Remove three sets.
SMT-890-3100 Tool assembly t 1 Q 4) Remove three balls (27).
SMT-890-3110 q Cylinder t 1 Q 5) Remove three gears (28) from carrier (23).
3 SMT-890-3120 q Piston t 1 Q 6) Remove two bearings (29) and remove
J spacer (30).
SMT-890-3130 q Shaft t 1 Q
SMT-890-3140 q Plate t 1 Q a Remove three sets.
5 SMT-890-1910 Installer t 1 Q 7) Remove snap ring (31) from gear (28).
a Remove three sets.
Disassembly 50-240 7. Hub and brake assembly

1. Cover assembly 1) Sling hub and brake assembly (32), remove
1) Remove 16 mounting bolts to remove cover 36 mounting bolts to remove assembly (32).
assembly (3). 2) Remove the O-ring and remove plate (33).
2) Remove the O-ring from cover (4).
3) Remove spacer (5). 8. Hub ring gear assembly
4) Remove three mounting bolts to remove 1) Remove eight mounting bolts, and then
shaft (6). remove retainer (34) and shims (35).
2. Sun gear shims for installation purpose.
Remove gear (7). 2) Remove hub ring gear assembly (36).
3) Remove the O-ring from tube (74).
3. Carrier assembly (large) 4) Remove two mounting bolts, and remove two
1) Remove four cap bolts, and remove carrier plates (37).
assembly (8). 5) Remove retainer (38) and remove the O-ring.
2) Remove the O-ring from carrier assembly 6) Remove floating seal (39) and remove the
(8). O-ring.
3) Remove four shafts (10) from carrier (9), and 7) Remove ball (40).
remove four balls (11). 8) Remove the inner race of roller bearing (41)
a Remove four sets. from hub (42).
4) Remove four gears (12) from carrier (9). 9) Remove 16 mounting bolts, and remove
a Remove four sets. eight plates (43).
5) Remove bearing (13) from gear (12). 10)Remove ring gear (44) from hub (42).
a Remove four sets.
6) Remove snap ring (14) from gear (12). 9. Wheel hub assembly
a Remove four sets. 1) Remove 61 stud bolts (45) from wheel hub
assembly (46).
4. Ring gear 2) Remove the outer race of roller bearing (41)
1) Remove 16 mounting bolts, and remove from hub (51).
eight plates (15). 3) Remove floating seal (47) and remove the
2) Remove ring gear (16). O-ring.
4) Remove retainer (48) and remove floating
5. Shaft assembly seal (49).
1) Remove shaft assembly (17). 5) Remove the O-ring from floating seal (49).
2) Remove snap ring (21) and gear (19). 6) Remove the O-ring from hub (51).
3) Remove spacer (20) from shaft (18). 7) Remove the outer race of roller bearing (50)
from hub (51).
10. Cylinder and piston assembly

1) Remove 16 mounting bolts, and then remove
cylinder (52).
2) Remove the O-ring from cylinder (52).
3) Remove oil seal (53) and remove floating
seal (54).
50-240 WA1200-6
Power train
4) Remove the O-ring from floating seal (54). Assembly 50-241

5) Remove plug (55) and remove the O-ring. 1. Tube
6) Remove bleeder (56). 1) Install retainer (72) to tube (74).
7) Remove plug (57) and remove the O-ring.
8) Remove three plugs (58).
9) Remove two plugs (59) and remove two
O-rings.
10)Remove two plugs (60) and remove two
O-rings.
11)Push in guide (61) to remove eight dowel
pins (62) and eight plates (63).
12)Remove eight guides (61) and remove eight
springs (64).
13)Remove piston (65) from cylinder (52).
14)Remove seals (66) and (67) from piston (65).
11. Discs and plates

1) Remove ten plates (68) and nine discs (69) 2) Install three washers (73) to tube (74), and
alternately. drive in the dowel pin.
2) Remove gear (71).
12. Tube
1) Remove the inner race of roller bearing (50).
2) Remove retainer (72) and then remove three
washers (73).
3) Remove 34 mounting bolts and remove gear
(75).
13. Gear
1) Remove plugs (78) and (79), and remove the
O-ring.
2) Remove spring pin (80).
3) Remove cap (81) and remove guide (82).
4) Remove lever (83) and remove shaft (84).
3) Press fit the inner race of roller bearing (50)
to tube (74).
a Shrink fit the inner race for press fit (ap-
prox. 60 °C).
WA1200-6 50-241
Power train
2. Gear 3. Disc wear indicator

1) Install inner gear (71) to tube (74). 1) Drive in spring pin (80) to lever (83) in a half
way.
2) Insert lever (83) from the inside of outer gear
(75).
2) Install O-ring (90) to tube (74).

2 O-ring:
Grease (G2-LI)
3) Insert the shaft (84) with the O-ring to lever
(83), and drive in spring pin (80).
3) Fit the guide bolt, set outer gear (75) to tube

(74), and install the gear with 34 mounting
bolts.
a Check the installed position.
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
50-242 WA1200-6
Power train
4. Discs and plates 5. Wheel hub assembly

1) Install ten plates (68) and nine discs (69) 1) Press fit the outer race of roller bearing (50)
alternately. to hub (51).
a Install the nine plates on the tube side a Expand fit the outer race for press fit (cool
aligning their tooth-missing parts with the for 30 minutes with dry ice).
disc wear indicator installation position. a Press fit the outer race until its end face
a Install the one plate on the piston side so comes in contact with the hub.
that it's tooth contacts with the disc wear
indicator.
2) Install O-ring (91) to hub (51).
2) Fit the O-ring, and install guide (82), cap (81)

and plug (78) to outer gear (75).
3 Guide:
237.7 to 321 Nm {24 to 33 kgm}
3 Cap:
117.6 to 161.7 Nm {12 to 16.5 kgm}
3) Fit the O-ring and install plug (79) to outer
gear (75).
3 Plug:
58.8 to 78.4 Nm {6 to 8 kgm}
3) Attach the dowel pin to retainer (48) and

install the retainer to hub (51).
WA1200-6 50-243
Power train
4) Install the floating seal to the retainer 4] Place floating seal (49) on O-ring (49a).
according to the following procedure. 2 Floating seal:
1] Install O-ring (49a) of the floating seal to Brake cooling oil (TO10)
retainer (48).
a Before installation, remove the whitish
bloom on the O-ring surface with
brake fluid (TO10).
a Check that the O-ring is free from twist
or adhesion of foreign objects.
5] While lightly holding floating seal (49) with

hand, push O-ring (49a) to floating seal
(49) with finger.
a While pushing in the O-ring, check
with the white marker pen marking to
prevent the O-ring from twisting.
2] After installing O-ring (49a), to check for a Markings (b) on the entire periphery
twist of the O-ring, put marking "b" with a must be visible uniformly.
white marker pen on the position where it
is visible from the outside.
a Put markings on the entire periphery
of the O-ring at regular intervals.
3] Apply brake cooling oil on the entire
periphery of O-ring (49a).
2 O-ring:
Brake cooling oil (TO10)
k Be careful not to let your fingers

caught while pushing the O-ring
(49a) to floating seal (49) with fin-
ger.
50-244 WA1200-6
Power train
a After installation, measure dimension 6) Install O-ring (47a) to floating seal (47).
"a" at four places on the periphery, 2 Floating seal:
and check that its dispersion is 1 mm Brake cooling oil (TO10)
or less. a Before installation, remove the whitish
bloom on the O-ring surface with brake
cooling oil (TO10).
a After installation, check that the O-ring is
free from twist.
7) Install floating seal (47) to hub (51).
2 Hub:
a Check that there is no damage or dust on
the O-ring contact surface on the hub.
a Use pushing jig J5 to install the seal.
a After installing the floating seal, check
that the O-ring is free from twist.
a After installing the floating seal, measure
dimension "a" at four places on the pe-
5) Reverse hub (51) and press fit the outer race riphery, and check that its dispersion is 1
of roller bearing (41). mm or less. (Similarly to floating seal
a Expand fit the outer race for press fit (cool (49).)
for 30 minutes with dry ice). 8) Install 61 stud bolts (45) to hub (51).
a Press fit the outer race until its end face a Screw in the stud bolt up to the incom-
comes in contact with the hub. plete thread portion.
a Check that each stud bolt has the identifi-
cation mark.
a Screw-in dimension (reference): 139 mm
3 Stud bolt:
441 to 883 Nm {45 to 90 kgm}
WA1200-6 50-245
Power train
6. Hub ring gear assembly 7. Adjusting preload of wheel bearing

1) Press fit the inner race of roller bearing (41) 1) Install wheel hub assembly (46) and hub ring
to hub (42). gear assembly (36) to tube (74).
2) Install ring gear (44) to hub (42). 2 Bearing:
3) Install eight plates (43) with 16 bolts. Axle oil (AXO80)
2 Mounting bolt: 2) Install preload adjustment jig J3 with three
Adhesive (LT-2) bolts.
3 Mounting bolt: 3) While checking with oil pressure gauge [2],
245 to 309 Nm {25 to 31.5 kgm} operate the hydraulic pump to apply the
4) Install ball (40). following specified hydraulic pressure to
5) Install the O-ring to retainer (38). preload adjustment jig J3.
6) Install retainer (38) to hub (42). a Specified pressure: 39.2 MPa
2 Retainer mounting portion: {400 kg/cm }2
Grease (G2-LI) 4) Close needle valve [3], and remove the
7) Install two plates (37) with two bolts. coupler.
2 Mounting bolt: 5) Turn the hub wheel assembly fully to fit in the
Adhesive (LT-2) bearing.
3 Mounting bolt: a Check that the pressure is 37.3 MPa
98 to 123 Nm {10.0 to 12.5 kgm}
{380 kg/cm2} or more. If the pressure
8) Install the O-ring to floating seal (39).
drops, apply the pressure again accord-
2 Floating seal:
ing to Step 3).
a Before installation, remove the whitish
bloom on the O-ring surface with brake
cooling oil (TO10).
a After installation, check that the O-ring is
free from twist.
9) Install the O-ring and floating seal (39) to
retainer (38).
2 Retainer:
a Check that there is no damage or dust on
the O-ring contact surface on the retainer.
a Use jig J5 to install the floating seal.
a After installing the floating seal, check
that the O-ring is free from twist.
a After installation, measure dimension "a"
at four places on the periphery, and check
that its dispersion is 1 mm or less. (Simi-
larly to floating seal (49).)
50-246 WA1200-6
Power train
6) Using a micro gauge, measure dimensions 8. Cylinder and piston assembly

"a" and "c" of the jig. 1) Install seals (67) and (66) to piston (65).
7) Using the depth micro gauge, measure a Install O-rings (67a) and (66a) first, then
dimension "b" between the cylinder upper install seals (67) and (66).
surface and the piston upper surface. a Before installing the seal, check that the
a Measure the distances at three places piston groove is free from damage or for-
and obtain the average. eign objects.
8) Calculate necessary shim pack thickness 2 Seal periphery:
"d". Grease (G2-LI)
q d = (a - b - c) + (0 – 0.1) mm
a Available shims: 0.2, 0.3, and 1.0 mm
a Obtain the necessary thickness by using
a minimum number of shims.
9) Remove wheel hub assembly (46) and hub

ring gear assembly (36).
2) Insert piston (65) to cylinder (52).

2 Piston surface:
Grease (G2-LI)
WA1200-6 50-247
Power train
3) Install eight springs (64) and eight guides 13)Install plug (55) with the O-ring to cylinder
(61). (52).
3 Plug:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
14)Check the brake seal according to the
1] Install the oil pressurization connector to
the pressurization port "a".
2] Feed oil through pressurization port "a",
and bleed air from bleeder "b".
3] Keep the piston pressure at 17.5 MPa
{178 kg/cm2}, and close the hand valve.
4] Check that the pressure drop is 0.29 MPa
{3 kg/cm2} or less in five minutes.
4) Reverse the cylinder.

5) Press fit the piston to the cylinder, attach
plate (63) to guide (61), and install dowel pin
(62).
15)Adjust the disc wear indicator according to

1] Apply pressure to the brake.
2] While keeping shaft (84) pushed in, turn
guide (82) so that the guide end face is
flush with the shaft end face, and then fix
6) Install the O-ring to cylinder (52). the guide with nut.
7) Install cylinder (52) to gear (75) with 16 bolts. 3 Nut:
3 Mounting bolt: 237.7 to 321 Nm {24 to 33 kgm}
824 to 1,030 Nm {84 to 105 kgm} 3] Install cap (81) to guide (82).
8) Install two O-rings, and install two plugs (60) 3 Cap:
to cylinder (52). 117.6 to 161.7 Nm {12 to 16.5
3 Plug: kgm}
58.8 to 78.4 Nm {6 to 8 kgm}
9) Install two O-rings, and install two plugs (59)
to cylinder (52).
3 Plug:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
10)Install three plugs (58).
11)Install plug (57) with the O-ring.
12)Install breather (56) to cylinder (52).
2 Threaded portion of bleeder:
50-248 WA1200-6
Power train
16)Referring to Step 4) of See "5. Wheel hub 12. Shaft assembly

assembly". install floating seal (54) to 1) Install spacer (20) to shaft (18).
cylinder (52). 2) Install gear (19) to shaft (18), and install snap
17)Install oil seal (53) to cylinder (52). ring (21).
2 Oil seal press fit portion: 3) Install shaft assembly (17).
LOCTITE 648
2 Oil seal lip: 13. Ring gear
Grease (G2-LI) 1) Install ring gear (16) to ring gear (44).
2) Install eight lock plates (15) with 16 bolts.
9. Wheel hub assembly and hub ring gear 2 Mounting bolt:
assembly Adhesive (LT-2)
1) Install wheel hub assembly (46). 3 Mounting bolt:
2 Bearing: 245 to 309 Nm {25 to 31.5 kgm}
Axle oil (AXO80)
2) Install hub ring gear assembly (36). 14. Carrier assembly (large)
2 Bearing: 1) Install snap ring (14) to gear (12).
Axle oil (AXO80) a Install four sets.
3) Fit selected shims (35) and retainer (34) with 2) Install bearing (13) to gear (12).
eight bolts. a Install four sets.
2 Mounting bolt: 3) Install four gears (12) to carrier (9) with four
Adhesive (LT-2) balls (11) and four shafts (10).
3 Mounting bolt: 4) Fit the O-ring to carrier assembly (8), and
1,520 to 1,910 Nm {155 to 195 kgm} install the assembly with four cap bolts.
3 Mounting bolt:
10. Hub and brake assembly 123 to 157 Nm {12.5 to 16 kgm}
1) Install plate (33) with the O-ring to tube (74). a When installing the carrier assembly to
2) Install hub and brake assembly (32) with 36 the hub, align drilled hole "b" under the
mounting bolts. drain plug of the carrier with through tap
3 Mounting bolt: hole "a" of the hub.
2,450 to 3,040 Nm {250 to 310 kgm}
11. Carrier assembly (small)

1) Install snap ring (31) to gear (28).
a Install three sets.
2) Fit spacer (30), and install two bearings (29).
a Install three sets.
3) Install three gears (28) to carrier (23) with
three balls (27) and three pins (26).
4) Install three snap rings (25).
5) Fit spacer (24) and install carrier assembly
(22).
WA1200-6 50-249
Power train
15. Sun gear

Install gear (7).
16. Cover assembly

1) Install shaft (6) to cover (4) with bolt (85) and
washer (86).
3 Bolt:
245 to 309 Nm {25 to 31.5 kgm}
2 Threaded portion of bolt:
Adhesive (LT-2)
2) Install three pins (87) and plate (88) to the
shaft.
3) Drive in two pins (87) to the plate, and install
spacer (89).
a Check that the pin edge is lower than the
spacer surface by 2 mm or more.
4) Drive pin (91) into spacer (90).
5) Install sun gear (18) to shaft (19).
6) Install snap ring (21), and then press in axle
shaft (18) fully.
7) Install sun gear (7) to the spline of carrier
assembly (22).
8) Fit the O-ring, and install carrier assembly (8)
with four cap bolts.
3 Bolt:
123 to 157 Nm {12.5 to 16 kgm}
9) Install spacer (90) by aligning its pin with the
hole of sun gear (19).
10)Fit the O-ring and install cover assembly (3)
with bolts.
3 Bolt:
245 to 309 Nm {25 to 31.5 kgm}
50-250 WA1200-6
Power train
Removal and installation of center support assembly
Removal and installation of center support assembly 50-251
Removal 50-251 2. Center support

k Before performing removal, be sure to imple- 1) Sling center support (3), remove the
ment "2. Preparatory work" and "3. Precau- mounting bolts, and then remove the center
tions during work" in "00 Safety notice". support. [*3]
a Take care not to damage the steering cyl-
1. Drive shaft inder rod when removing the center sup-
1) Sling center drive shaft (1) and remove it. port.
[*1] 4 Center support assembly:
4 Center drive shaft: 164 kg
190 kg
2) Sling and remove front drive shaft (2).
[*2]
a Move the front drive shaft toward the front
differential side, and while moving the
center support side aside, remove the
faucet joint portion of the differential side.
280 kg
WA1200-6 50-251
Power train
Removal and installation of center support assembly
Installation 50-252
moval.
[*1]
343 to 427 Nm {35 to 43.5 kgm}
[*2]
343 to 427 Nm {35 to 43.5 kgm}
[*3]
a When installing the center support, shim adjust-
ment is unnecessary.
3 Center support mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
50-252 WA1200-6
Power train
Disassembly and assembly of center support
Disassembly and assembly of center support 50-253

Disassembly 50-253
1. Retainer 3. Retainer
Remove three mounting bolts (2) of retainer (1). 1) Remove the mounting bolts to remove
retainer (7).
2) Remove the O-ring in the joint portion.
2. Coupling
1) Turn over the center support assembly.
2) Remove bolt (3) and remove holder (4), 4. Shaft
coupling (5) and shim (6). 1) Set the shaft and housing assembly (8) on
a Note the thickness and quantity of the the press stand.
shims. 2) Push out shaft (9) using the press.
a Take care not drop the shaft to the floor
directly.
WA1200-6 50-253
Power train
3) Remove bearing (10) and retainer (1) from Assembly 50-254

the shaft. 1. Housing
1) Install outer races (12) to the housing.
2) Install the O-rings to both ends of the
housing.
5. Oil seal
Remove oil seal (11) from retainers (1) and (7).
2. Oil seal
Using a push tool, install oil seal (11) to retainers
(1) and (7).
a Press fit oil seal (11) until it reaches the re-
tainer.
q Reference dimension (a) = 2 ± 0.5 mm
2 Oil seal lip:
Grease (G2-LI)
6. Housing
Remove outer races (12) from the housing.
50-254 WA1200-6
Power train
3. Shaft 4. Retainer
1) Install retainer (1) to the shaft. 1) Install retainer (7).
2) Using a push tool, install bearing (10) to shaft a Fill inner space (c) with grease (G2-LI).
(9). 3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
3) Install housing (13) to shaft (9).

a Fill inner space (b) with grease (G2-LI). 5. Shim adjustment
4) Tighten mounting bolts (2) of retainer (1). 1) Install coupling (5), holder (4) and bolt (3).
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
5) Using a push tool, install bearing (14).
a Install coupling (5) aligning its matchmark

(A) with matchmark (B) of shaft (9).
a Measure the thickness of the holder.

a Do not install shims.
2) While rotating the housing (13), tighten bolt
(3) so that the starting torque of the housing
is 8 to 12 Nm {0.8 to 1.2 kgm}.
3 Bolt (3):
245 Nm {25 kgm}
WA1200-6 50-255
Power train
5) To obtain the specified amount of end play,

select shims so that the thickness of shim
pack (6) is within the following value, and
then install the shims.
q Available shims: 0.05, 0.1, and 0.3 mm
q Shim pack thickness = (f) + 0.1 to (f) +
0.15 mm
6) While rotating the housing (13), tighten bolt
(3) to the following torque.
3 Bolt:
2,450 to 3,040 Nm {250 to 310 kgm}
3) Measure clearance (d) between holder (4)

and shaft (9) at three holder holes (e).
4) Calculate average value (f) of clearance (d).
7) Set dial gauge [1] to the end surface of

coupling (5). Move coupling (5) up and down
with housing (13) fixed, and check that the
end play is within the standard value range.
q End play: 0.05 to 0.15 mm
6. Greasing
Fill housing (13) with grease of 3,000 CD
through the grease filler port of the housing.
2 Inside of housing:
Grease (G2-LI)
50-256 WA1200-6
Steering system
Removal and installation of steering demand valve assembly

Removal and installation of steering demand valve assembly 50-257


6 Hydraulic oil: 3 Valve assembly mounting bolt:
approx. 1,125 l 235 to 285 Nm {23.5 to 29.5 kgm}
2. Disconnect tubes (1) and (2). q Refilling with oil (hydraulic tank)
Refill the hydraulic tank with oil through the oil
3. Disconnect hoses (3), (4), and (5). filler to the specified level. Run the engine to
4. Remove U-bolts and disconnect tubes (6), (7), the oil level again.
and (8).
q Air bleeding
5. Sling steering demand valve assembly (9), Bleed air from the piston pump and work equip-
remove three mounting bolts (10), and then ment hydraulic circuit. For details, see "Bleeding
remove the steering demand valve assembly air from piston pump" and "Bleeding air from
together with the bracket. [*1] work equipment hydraulic circuit and steering
4 Steering demand valve assembly: hydraulic circuit".
70 kg
a The above removal procedure is described
based on the right steering demand valve as-
sembly. The left steering demand valve as-
sembly is removed in the similar way.
WA1200-6 50-257
Steering system
Removal and installation of steering cylinder assembly
Removal and installation of steering cylinder assembly 50-258
Removal 50-258
1. Disconnect grease hose (1) and remove the

nipple.
3. Start the engine and then retract the piston rod.

4. Disconnect cylinder bottom hose (9) and
cylinder head hose (10).
2. Remove the steering cylinder pin (on the rear

frame side) according to the following proce-
dure.
1) Remove four upper mounting bolts (2) and
six retainer lock bolts (2a) of pin (8).
k Pin (8) may come off when you remove
the bolts. Be sure to support the pin at
the bottom.
2) Remove retainer (3).
3) Install eyebolts into two bolt holes (at the
diagonal positions) of pin (8) and sling pin (8).
5. Disconnect grease hose (11) and remove the
a Thread diameter: 24 x 3
nipple.
Stem length: 77 mm (threaded portion
length: 43 mm)
4) Remove bushing (6).
5) Remove four lower mounting bolts (4) of pin
(8).
6) Remove plate (5) and bushing (7).
a Pull out bushing (7) by screwing the forc-
ing bolt into the tapped hole of plate (5).
a Bushing (7) and plate (5) may fall off
when pulling out bushing (7), so set
something to catch them.
7) Sling and remove pin (8).
a Push the head of pin (8) down to loosen
bushing (6), then pin (8) can be removed.
4 Steering cylinder pin:
50 kg
50-258 WA1200-6
Steering system
6. Sling steering cylinder assembly (12). Installation 50-259

7. Remove the steering cylinder pin (on the moval.
cylinder bottom side) according to the following
procedure. q Flushing of hydraulic circuits
1) Remove four upper mounting bolts (13) and When repairing the steering cylinder that is inter-
six retainer lock bolts (13a) of pin (8a). nally damaged, perform flushing of hydraulic
k Pin (8a) may come off when you re- circuits. For details, see "Flushing procedure for
move the bolts. Be sure to support the work equipment and steering circuit".
pin at the bottom.
2) Remove retainer (14).
3) Install eyebolts into two bolt holes (at the
diagonal positions) of pin (8a) and sling pin
(8a).
a Thread diameter: 24 x 3
Stem length: 77 mm (threaded portion
length: 43 mm)
4) Remove bushing (17).
5) Remove four lower mounting bolts (15) of pin
(8a).
a Pull out bushing (18) by screwing the
forcing bolt into the tapped hole of plate
(16).
a Bushing (18) and plate (16) may fall off
when pulling out bushing (18), so set
something to catch them.
7) Sling and remove pin (8a).
a Push the head of pin (8a) down to loosen
bushing (17), then pin (8a) can be re-
moved.
4 Steering cylinder pin:
50 kg
8. Sling and remove steering cylinder assembly
(12) while moving it backward.
4 Steering cylinder assembly:
590 kg
WA1200-6 50-259
Steering system
q Install the steering cylinder pin (on the cylinder 9) Tighten the lower four mounting bolts (15) to
bottom side) according to the following proce- the specified torque.
dure. a Be sure to tighten the upper mounting
a Completely wipe off grease and lubricant ad- bolts to the specified torque first, then
hered to periphery of pin, inner surface of tighten the lower mounting bolts to the
bushing (a), and taper surface of taper bush- specified torque.
ing (b). 3 Mounting bolt:
a When installing the steering cylinder pin, be 824 to 1,030 Nm {84 to 105 kgm}
careful not to put grease and lubricant on pe-
riphery of pin, inner surface of bushing (a),
and taper surface of taper bushing (b).
1) Sling the steering cylinder, and align the pin
mounting hole in the steering cylinder bottom
with that in the front frame (temporary
setting).
2) To prevent the steering cylinder bottom from
disengaging, tie the cylinder rod to the rear
frame, and then remove the sling.
a It is easy to install the piston rod to the
rear frame if the pin mounting portion of
the piston rod is set on a level with that of
the rear frame.
3) Install eyebolts into two pin bolt holes (at the
diagonal positions) and sling pin (8a) to
install.
k Be sure to support the pin at the bot-
tom.
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin
holes.
a Face grease hole (c) of the pin toward the
inside of the chassis.
4) Install bushing (17).
a Install the bushings so that their mating
faces (d) are in the horizontal direction.
5) Remove two eyebolts.
6) Install retainer (14) and partially tighten six
retainer lock bolts (13a) and four pin
mounting bolts (13).
7) Install bushing (18) and plate (16) under the
pin (8a), and tighten four mounting bolts (15)
lightly.
faces (e) are in the horizontal direction.
8) Tighten four upper mounting bolts (13) and
six retainer lock bolts (13a) of pin (8a) to the
specified torque.
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
50-260 WA1200-6
Steering system
q Install the steering cylinder pin (on the rear frame 8) Tighten the lower four mounting bolts (4) to
side) according to the following procedure. the specified torque.
a Completely wipe off grease and lubricant ad- a Be sure to tighten the upper mounting
hered to periphery of pin, inner surface of pis- bolts to the specified torque first, then
ton rod bushing (a), and taper surface of tighten the lower bolts to the specified
taper bushing (b). torque.
a When installing the steering cylinder pin, be 3 Mounting bolt:
careful not to put grease and lubricant on pe- 824 to 1,030 Nm {84 to 105 kgm}
riphery of pin, inner surface of piston rod
bushing (a), and taper surface of taper bush-
ing (b).
1) Align the pin mounting hole in the cylinder rod
with that in the rear frame.
2) Install eyebolts into two pin bolt holes (at the
diagonal positions) and sling pin (8) to install.
tom.
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin
holes.
a Face grease hole (c) of the pin toward the
inside of the chassis.
3) Install bushings (6).
retainer lock bolts (2a) and four pin mounting
bolts (2).
6) Install bushing (7) and plate (15) under the
pin (8), and tighten four mounting bolts (4)
lightly.
faces (e) are in the horizontal direction.
7) Tighten four upper mounting bolts (2) and six
retainer lock bolts (2a) of pin (8) to the spec-
ified torque.
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
WA1200-6 50-261
Steering system
Removal and installation of emergency diverter valve assembly
Removal and installation of emergency diverter valve assembly 50-262
Removal 50-262 3. Removal of the diverter valve assembly (lower).

k Before performing removal, be sure to imple- 1) Disconnect harness connector R11 (8).

6 Hydraulic oil:
approx. 1,125 l
2. Removal of the diverter valve assembly (upper).
1) Disconnect harness connector R12 (1).
2) Remove suction tube (9).

3) Disconnect hoses (10), (11), (12) and (13).
4) Sling diverter valve assembly (14), remove
mounting bolts, and remove the assembly.
2) Remove suction tube (2).

3) Disconnect hoses (3), (4), (5) and (6).
4) Sling diverter valve assembly (7), remove
mounting bolts, and remove the assembly.
50-262 WA1200-6
Steering system
Removal and installation of emergency diverter valve assembly
Installation 50-263
moval.
q Flushing of hydraulic circuits

When repairing the valve that is internally
damaged, perform flushing of hydraulic circuits.
For details, see "Flushing procedure for work
equipment and steering circuit".
q Refilling with oil (hydraulic tank)

Supply oil through the oil filler port to the speci-
fied level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
q Air bleeding
Bleed air from the piston pump and work equip-
ment circuit. For details, see "Bleeding air from
piston pump" and "Bleeding air from work equip-
ment circuit and steering circuit".
WA1200-6 50-263
Steering system
Removal and installation of emergency steering pump assembly
Removal and installation of emergency steering pump assembly 50-264

k Before performing removal, be sure to imple- q perform installation in the reverse order to re-
ment "2. Preparatory work", "3. Precautions moval.
[*1]
1. Drain the hydraulic oil. 3 Pump assembly mounting bolt:
6 Hydraulic oil: 245 to 309 Nm {25 to 31.5 kgm}
approx. 1,125 l
2. Disconnect hose (1). q Flushing of hydraulic circuits
3. Disconnect hose (2). When repairing the pump that is internally
4. Disconnect hose (3). damaged, perform flushing of hydraulic circuits.
5. Sling emergency steering pump assembly (4), For details, see "Flushing procedure for work
remove mounting bolts, and remove the equipment and steering circuit".
assembly. [*1]
a Take the same procedure to remove the low- q Refilling with oil (hydraulic tank)
er emergency steering pump assembly. Supply oil through the oil filler port to the speci-
4 Emergency steering pump assembly fied level. Run the engine to circulate the oil
(1 unit): through the system. Then check the oil level
50 kg again.
q Air bleeding
Bleed air from the piston pump and work equip-
ment circuit. For details, see "Bleeding air from
piston pump" and "Bleeding air from work equip-
ment circuit and steering circuit".
50-264 WA1200-6
Brake system
Removal and installation of brake accumulator charge valve assembly
Brake system 50-265

Removal and installation of brake accumulator charge valve assembly 50-265

1. Remove brake oil tank return tube (T) (1). q Air bleeding
Bleed air from the brake hydraulic circuit. For
details, see "Bleeding air from the brake
hydraulic circuit".
2. Disconnect hose (P1) (2) from the strainer (from

brake pump).
3. Disconnect hose (PP) from the brake accumu-

lator.
4. Remove tube (P2) (4) to the brake accumulator.
5. Remove mounting bolt (5) and then remove

brake accumulator assembly (6).
WA1200-6 50-265
Brake system
Removal and installation of brake oil tank assembly
Removal and installation of brake oil tank assembly 50-26

k Before performing removal, be sure to imple- q Perform installation in the reverse order to re-
ment "2. Preparatory work", "3. Precautions moval.
during work" in "00 Safety notice". [*1]
3 Brake oil tank mounting bolt:
1. Drain the oil from the brake tank. 824 to 1,030 Nm {84 to 105 kgm}
6 Brake tank:
approx. 105 l q Refilling with oil (brake oil tank)
2. Disconnect the level sensor harness connectors Refill hydraulic oil through the oil filler port to the
HR6 and HR10 (1) of the brake oil tank. specified level.
q Air bleeding
Bleed the air from the brake circuit. For details,
see "Bleeding air from brake circuit".
3. Disconnect brake suction tube (2).

4. Disconnect brake return tube (3).
5. Disconnect brake cooler suction tube (4).
6. Disconnect brake cooler return tube (5).
7. Disconnect drain hose (6).
8. Sling brake oil tank assembly (7), remove
mounting bolts (8), and remove the assembly.
[*1]
4 Brake oil tank assembly:
225 kg
50-266 WA1200-6
Procedure for disconnecting front frame and rear frame

Procedure for disconnecting front frame and rear frame 50-267
1. Cover the firm and level ground with iron plate,

place the machine on the plate, and lower the
bucket to sei it horizontal on the ground.
2. Raise rear frame (1) off the ground with jacks so
that truck (3) can be placed under front frame
(2).
3. Place truck (3) under front frame (2), and lower
rear frame (1) until front tires (4) and bucket (5)
are placed on the truck.
4. Support rear frame (1) and the rear of front frame
(2) with support stand or jacks [1] and [2].
a Align the center pin mounting portion of the
rear and front frames precisely.
a Support stand or jacks [1] and [2] must be for
30-ton load. 8. Remove parts to be replaced from the frame and
a Use truck (3) for 100-ton load. replace them with new ones.
9. After completing replacement of parts, return the
front frame to the original position, and install the
upper hinge pin and lower hinge pin.
a For procedure for installation and adjust-
ment, see "Removal and installation of center
hinge pin".
Shape of truck [Example]

q (4): Four track rollers of PC800
k After setting the truck under the front

frame, be sure to implement "2. Prepara-
tory work", "3. Precautions during work"
in "00 Safety notice".
5. Remove the steering cylinder pin (on the rear

frame side), hydraulic piping around the center
hinge, and the center drive shaft.
a See "Removal and installation of center
hinge pin".
6. Remove the lower hinge pin and upper hinge
pin.
a See "Removal and installation of center
hinge pin".
7. Tow truck (3) with other machine or winch to
move front frame (2) and disconnect it from rear
frame (1).
WA1200-6 50-267
Removal and installation of center hinge pin
Removal and installation of center hinge pin 50-268
Special tools 50-268 Removal 50-268

New/redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name during work" in "00 Safety notice".
bol
1. Work equipment assembly
790-314-1000 Puller t 1 Remove the work equipment assembly. For
790-101-40000 Puller t 1 details, see "Removal and installation of work
790-101-1102 Pump t 1 equipment assembly".
SMT-890-2120 q Guide t 1 Q 2. Operator's cab and floor assemblies
SMT-890-2150 q Guide t 1 Q Remove the operator's cab and floor assembly.
SMT-890-2160 q Guide t 1 Q For details, see "Removal and installation of
SMT-890-2170 q Plate t 1 Q operator's cab and floor assembly".
1 SMT-890-2180 q Bolt t 1 Q
01643-33690 q Washer t 2 3. Steering cylinder pin (on the rear frame side)
01580-03629 q Nut t 2
1) Remove four upper mounting bolts (5) and
SMT-890-2140 q Guide t 1 Q six retainer lock bolts (6) of pin (1).
SMT-890-2210 q Guide t 1 Q k Pin (1) may come off when the bolts
SMT-890-2220 q Guide t 1 Q are removed. Be sure to support the
791-775-1140 q Bolt t 1 pin at the bottom.
K
01643-33080 q Washer t 2 2) Remove retainer (7).
01582-03024 q Nut t 2 3) Install eyebolts into two pin bolt holes (at the
2 790-101-4000 Puller t 1
790-101-1102 Pump t 1
diagonal positions) and sling pin (1).
SMT-890-2300 Push tool t 1 Q a Thread diameter: 24 x 3
SMT-890-2310 q Sleeve t 1 Q Stem length: 77 mm (threaded portion
SMT-890-2320 q Sleeve t 1 Q length: 43 mm)
SMT-890-2330 q Plate t 1 Q 4) Remove bushing (8).
SMT-890-2210 q Guide t 1 Q 5) Remove four lower mounting bolts (2) of pin
SMT-890-2220 q Guide t 1 Q (1).
791-775-1140 q Bolt t 1
01643-33080 q Washer t 2
01532-03034 q Nut t 2 7) Sling pin (1) and remove it.
SMT-890-2410 Push tool t 1 Q 4 Steering cylinder pin:
SMT-890-2420 Push tool t 1 Q 50 kg
3
50-268 WA1200-6
5. Center drive shaft

Sling and remove center drive shaft (17).
[*4]
190 kg
4. Hydraulic piping
Disconnect the following hoses from the front
frame.
q Hoses (12) between steering pump and
steering demand valve.
q Hoses (13) between switch pump and steer- 6. PPC hose and harness
ing demand valve. Disconnect the following hoses and harnesses.
q Hoses (14) between work equipment pump q Hoses (18) and (19) between EPC valve and
and work equipment valve. work equipment valve.
q Hose (15) between hydraulic oil cooler and q Hoses (20) and (21) between rotary valve
steering demand valve. and steering demand valve.
q Hoses (16) between hydraulic tank and work q Auto greasing hose (22)
equipment valve. q Brake hose(23)
q Wiring harness (24)
a Tag each hose for identification.
WA1200-6 50-269
7. Supporting frame 8. Lower hinge pin

1) Using a crane, etc., place stand [1] under the 1) Remove mounting bolts (27) and (28), then
front frame. remove retainer (29).
a Shims (30) are between the retainer and
frame. Note the number and thickness of
the shims for installation purpose.
2) Remove bolt (31), install the eyebolt, and
sling and remove lower hinge pin (32).
3) Remove spacer (33).
2) Using a crane, etc., place stands [2] and [3]

under the rear frame.
9. Upper hinge pin

1) Remove mounting bolts (34) and (35), then
remove retainer (36).
2) Using mounting bolt holes (34), install two
eyebolts to sling and remove upper hinge pin
(37).
50-270 WA1200-6
10. Disconnecting frames

Remove the lock bar, and move front frame (57)
forward to disconnect it from rear fame (58).
a The distance of one movement should be
about 100 mm.
k Move the front frame with extreme care.
6) Remove bearing (46).
11. Rear frame

1) Remove bushing (38) from the top of the
frame.
2) Remove bushing (39) from the bottom of the
frame.
3) Remove plate (40) and remove dust seal
(41).
4) Remove mounting bolt (42) and retainer (43).
frame. Note the number and thickness of 12. Front frame
the shims for installation purpose. 1) Remove mounting bolt (47) and retainer (48).
frame. Note the number and thickness of
the shims for installation purpose.
2) Remove plate (50) and remove dust seal
(51).
5) Remove dust seal (45) from retainer (43).
WA1200-6 50-271
3) Remove dust seal (52) from retainer (48). Installation 50-272

moval.
q Install the steering cylinder pin (on the rear frame
side) according to the following procedure.
a Completely wipe off grease and lubricant on
the periphery of pin, inner surface of piston
rod bushing (a), and tapered surface of taper
bushing (b).
a When installing the steering cylinder pin, be
careful not to put grease and lubricant on pe-
riphery of pin, inner surface of piston rod
bushing (a), and tapered surface of taper
bushing (b).
1) Align the pin mounting hole in the cylinder rod
4) Remove bearing (53). with that in the rear frame.
5) Remove bushings (54) and (55). 2) Install eyebolts into two pin bolt holes (at the
diagonal positions) and sling pin (1) to install.
tom.
k When aligning the pin holes, use a bar,
etc. Never insert your fingers in the pin
holes.
a Install the pin with grease hole (c) facing
inside the machine.
3) Install bushings (8).
retainer lock bolts (6) and four pin mounting
bolts (5).
6) Install bushings (4) and plate (3) at the
bottom of pin (1), and install four mounting
bolts (2).
3 Mounting bolt:
824 to 1030 Nm {84 to 105 kgm}
7) Tighten four lower mounting bolts (5) and six
retainer lock bolts (6) of pin (1) to the speci-
fied torque.
3 Mounting bolt:
824 to 1030 Nm {84 to 105 kgm}
50-272 WA1200-6
Procedure for installing center hinge pin 50-273

1. Using tool K3, install dust seals (52) and (45) to
retainers (48) and (43) with their seal lips (56)
facing outward.
a For tool K3, see the "Sketches of special
tools"
q Retainer (48): SMT-890-2440 (Tool part
No.)
q Retainer (43): SMT-890-2420 (Tool part
No.)
(RH: Right side of machine, LH: Left side of ma-

chine)
2. Front frame
1) Using tool K1, press fit bearing assembly
(53) to the top of frame (57).
tools".
a Check that the bearing outer race are
[*4] press fitted to the bottom.
3 Bore of frame in which bearing is
3 Center drive shaft mounting bolt:
343 to 427 Nm {35 to 43.5 kgm} press fit:
Molybdenum disulphide lubricant
(LM-P)
a The bearing consists of selective combi-
nation parts and its clearance is adjusted
properly. Do not change the combination
parts.
a When assembling the bearings, apply
grease sufficiently inside the bearings.
WA1200-6 50-273
2) Install retainer (48) and partially tighten six 6) Using tool K3, install dust seal (51) to the
mounting bolts (47). frame with seal lip (56) facing outward, and
a Be careful not to tighten the bolts uneven- install plate (50) as a stopper.
ly. a For tool K3, see the "Sketches of special
3 Mounting bolt: tools".
137 Nm {14 kgm} ± 10% q Tool part No.: SMT-890-2430
3) Loosen mounting bolts (47) once, and tighten
them again to the torque specified in Step 2)
taking care not to tighten them unevenly.
4) Measure the clearance between retainer (48)
and front frame (57) at four equally divided
points on the circumference, and calculate
average clearance "d".
Select shims (49) so that average clearance
"d" is within the range of 0.08 mm to 0.18
mm.
a The shim pack thickness must not be
larger than the individually measured
clearance.
5) Install shims (49) selected in Step 4)
between retainer (48) and front frame (57),
and tighten retainer (48) with mounting bolts
(47).
3 Mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
7) Using tool K2, press fit bushings (54) and

(55) to the hinge portion at the bottom of the
frame.
tools".
50-274 WA1200-6
3. Rear frame
1) Using tool K1, press fit bearing assembly
(46) to the bottom of frame (58).
tools".
a Check that the bearing outer race are
press fitted to the bottom.
a The bearing consists of selective combi-
nation parts and its clearance is adjusted
properly. Do not change the combination
parts.
a When assembling the bearing, apply
grease sufficiently inside the bearing.
6) Using tool K3, install dust seal (41) at the

bottom of the frame with seal lip (56) facing
outward, and install plate (40) as a stopper.
tools".
q Tool part No.: SMT-890-2410
2) Install retainer (43) and partially tighten ten

a Be careful not to tighten the bolts uneven-
ly.
3 Mounting bolt:
441 Nm {45 kgm} ± 10%
3) Loosen mounting bolts (42) once, and tighten
them again with the torque specified in Step 7) Install bushing (39) to the hinge portion at the
2) taking care not to tighten them unevenly. bottom of the frame.
4) Measure the clearance between retainer (43)
and rear frame (58) at four equally divided
points on the circumference, and calculate
average clearance "e".
"e" is within the range of 0.08 mm to 0.18
mm.
clearance.
between retainer (43) and rear frame (58),
and tighten retainer (43) with mounting bolts
(42).
2 Mounting bolt:
Adhesive (LOCTITE #262)
3 Mounting bolt:
2,450 to 3,040 Nm {250 to 310 kgm}
WA1200-6 50-275
8) Install bushing (38) to the hinge portion at the 5) Remove retainer mounting bolts (34) and
top of the frame. (35) one by one, apply LOCTITE, and tighten
them to the specified torque.
a Completely degrease threads and taps.
2 Mounting bolts (34) and (35):
824 to 1,030 Nm {84 to 105 kgm}
4. Connecting frames
Move the front frame backward to connect it with
the rear frame, and fit the lock bar.
k Move the front frame with extreme care.
5. Upper hinge pin

1) Install retainer (36) to upper hinge pin (37), 6. Lower hinge pin
tighten two mounting bolts (34), and install 1) Insert lower hinge pin (32) into the lower
two eyebolts in the remaining bolt holes. hinge, insert bushing (33), and partially
2) Insert upper hinge pin (37) through front tighten retainer (29).
frame (57) and rear frame (58), and remove 2) Place the jack under the bottom of the lower
the eyebolts. hinge of rear frame (58) to keep front frame
3) Tighten four mounting bolts (34) and six (57) and bushing (39) closely contact and no
mounting bolts (35) of retainer (36), and then space between them.
hit the head of upper hinge pin (37) three to 3) Tighten ten mounting bolts (27) and four
five times with a copper hammer. mounting bolts (28) of retainer (29), and then
3 Mounting bolts (34) and (35): hit the head of lower hinge pin (32) three to
824 to 1,030 Nm {84 to 105 kgm} five times with a copper hammer.
4) To fit in contact parts with each other, repeat 3 Mounting bolts (27) (M36):
Step 3) three times, and then tighten retainer 2,450 to 3,040 Nm {250 to 310 kgm}
mounting bolts (34) and (35) again to the 3 Mounting bolts (28) (M45):
torque specified in Step 3). 4,510 to 5,490 Nm {460 to 560 kgm}
4) To fit in contact parts with each other, repeat
Step 3) three times, and then tighten retainer
mounting bolts (27) and (28) again to the
torque specified in Step 3).
50-276 WA1200-6
5) Taking care not to move rear frame (58), q Refilling

remove all of the ten bolts (27), and measure Supply hydraulic oil through the oil filter port to
clearance "f" between retainer (29) and front the specified level.
frame (57) at three points (120 deg. interval) 5 Hydraulic oil:
on the circumference with feeler gauge. Then approx. 1,125 l
calculate average clearance "f".
"f" is within the range of 0.08 mm to 0.18 mm.
clearance.
between retainer (29) and front frame (57),
and then repeat Steps 3) and 4) again.
7) Remove retainer mounting bolts (27) and
(28) one by one, apply LOCTITE, and tighten
them to the specified torque.
a Completely degrease threads and taps.
3 Mounting bolts (27) (M36):
2,450 to 3,040 Nm {250 to 310 kgm}
3 Mounting bolts (28) (M45):
4,510 to 5,490 Nm {460 to 560 kgm}
8) Remove the jack that was placed under the

bottom of lower hinge in item 2).
a After completing the assembly, pump
grease to the upper hinge pin, lower
hinge pin, and steering cylinder shaft until
grease spills out of the respective dust
seal portions.
WA1200-6 50-277
q Greasing
Use the auto-greasing system to grease the center hinge pin according to the following procedure.
UH: Upper hinge pin UI: Injector for upper hinge FF: Front frame RF: Rear frame
pin
LH: Lower hinge pin LI: Injector for lower hinge
pin
1. Refill of grease into grease pump case 2) Check that grease does not leak between
1) Check with level indicator (1) that grease is grease pump case (2) and follower plate (2).
inside grease pump case (2). a Be sure to use follower plate (3).
a Supply the grease if the level is low. (If follower plate (3) is not used, the pump
5 Grease pump case: cannot suction grease even if a sufficient
Lithium grease (G2-LI) volume of grease is in the grease pump
case.)
50-278 WA1200-6
3) Turn starting switch (4) to ON position, and 2. Operation of auto-greasing system

check that auto-greasing indicator lamp (L) 1) The auto-greasing system starts automati-
lights up on the monitor panel. cally when starting switch (4) of the machine
q Lamp on: Normal is turned to ON position.
q Lamp off: Circuit is open, main piping is 2) Pressing auto-greasing switch (5) starts the
broken, or grease inside the grease pump grease pump irrespective of the timer.
is empty. a The grease pump is only activated while
you are pressing switch (5). If you release
the switch, the grease pump stops.
a Auto-greasing switch (5) should be used
in the following cases:
q When checking operation of the
grease pump
q When greasing additionally
In the following cases, the lamp blinks at

interval of 5 seconds.
1] Greasing is impossible because; no
grease is inside the grease pump,
greasing circuit is damaged, or pres-
sure inside the circuit does not rise up
to the specified pressure while the
pump is operating.
2] Power shutoff
The system does not function
because power supply is shut off.
3] Depressurization disabled
Circuit pressure does not drop and
plunger does not return after one
greasing cycle, and the next greasing
cycle cannot be started.
4] While pressure inside the circuit rises
up to the specified level.
WA1200-6 50-279
3. Adjusting delivery from injector 5] Tighten plugs (8) so that no leakage may
q Injectors (UI) and (LI) is activated by pres- occur.
sure from the pump, and deliver the set vol- a The pressure gauge does not indicate
ume of grease to bearings. whether air is bled.
q Perform greasing at the maximum delivery a If only small volume of air is left in the
rate after installation of the center pin. circuit, the system operates normally
1) Loosen lock nut (6). because the delivery of grease pump
2) Tighten adjustment screw (7) clockwise until is high.
it contacts stopper. a Whether or not the system runs nor-
(Minimum delivery 0.13 cc/stroke) mally is determined by whether the
3) Rotate adjustment screw (7) ten turns coun- grease pump stops in balance within a
terclockwise to loosen the screw. predefined time (operating time (60
(Maximum delivery: 1.3 cc/stroke) sec.)).
4) Tighten lock nut (6).
a Lock the adjustment screw with wrench f
so that it may not be rotated with the nut.
(Reference) Increment of delivery per
turn: 0.13 cc
4. Bleeding air from auto-greasing system

a The work must be done by two workers.
1) Bleeding air from main line
1] A worker removes plugs (8) installed on
injectors (UI) and (LI).
2] Another worker presses the
auto-greasing switch to start the grease
pump. 2) Bleeding air from pressure switch portion
3] Discharge grease mixed with air (milky) 1] A worker removes pressure switch (10)
from the air bleeding ports of the injec- installed on block (9) of the auto-greasing
tors. unit.
4] When normal grease comes out, press (For this auto-greasing unit, the block is
the auto-greasing switch to stop the installed on the rear left of the operator's
grease pump. cab.)
2] Another worker must presses the
pump.
3] Discharge grease mixed with air (milky)
from block (9).
50-280 WA1200-6
4] When normal grease comes out, press

the auto-greasing switch to stop the 5. Checking the supply line pressure
grease pump. Check that grease pump pressure gauge (11)
5] Install pressure switch (10) on block (9). and grease supply line pressure gauge (10) indi-
a Make sure that no grease is leaked. cate the following pressure values.
q Grease pump pressure gauge:
(Normal value) 2.06 MPa {21 kg/cm2}

q Grease supply line pressure gauge:
(Normal value) 20.6 MPa {210 kg/cm2}
3) Bleeding air from supply line pressure

gauge portion
1] A worker removes grease supply line
pressure gauge (11) installed on block (9)
of the auto-greasing unit.
(For this auto-greasing unit, the block is
installed on the rear left of the operator's
cab.)
2] Another worker presses the
pump.
3] Discharge grease mixed with air (milky)
from block (9).
4] When normal grease comes out, press
the auto-greasing switch to stop the
grease pump.
5] Install supply line pressure gauge (11) on
block (9).
a Make sure that no grease is leaked.
a If air is left inside the circuit, the

grease pressure may not rise up to the
specified level, or the injector does not
work normally as it takes long time un-
til specified pressure is reached.
WA1200-6 50-281
6. Checking operation of injector 2) Check that indicator pin (12) runs normally.
1) Turn starting switch (4) to ON position, and
press auto-greasing switch (5).
7. Greasing to the center hinge pin

1) Turn starting switch (4) to ON position, and
press auto-greasing switch (5).
50-282 WA1200-6
2) Keep pumping new grease until it spills out of 2) Set fitting (15) of the grease gun to grease
the center hinge pin. fitting (14).
3) Keep pumping new grease until it spills out of
the center hinge pin.
3) If new grease does not spill out of the P,

perform the following procedures.
1] Perform Steps 1 to 4 again.

a If no problems are found even after
performing Steps 1 to 4, the grease
pump or injector may fail. Repair the
unit and perform greasing again.
2] Perform Step 8 "manual greasing".
8. Manual greasing
q If greasing by "auto-greasing system" cannot
be performed, use a grease gun for manual
greasing.
1) Remove cap (13) from injectors (UI) and (LI).
4) When greasing is completed, fit the cap.
q Air bleeding
Bleed the air from the brake circuit. For details,
see “Bleeding air from brake circuit”.
WA1200-6 50-283
Hydraulic system
Removal and installation of hydraulic tank, filter case assembly

Removal and installation of hydraulic tank, filter case assembly 50-284
Removal 50-284 6. Disconnect hydraulic oil temperature sensor

k Before performing removal, be sure to imple- connector HS1 (6).
tions during work" in "00 Safety notice". 7. Remove couplings (7) and (8).
1. Drain the hydraulic oil. 8. Sling suction tube (9), disconnect bracket (10)
6 Hydraulic oil: and remove suction tube (9).
approx. 1,125 l
9. Disconnect tubes (11), (12), and (13).
3. Lift and remove step (3).
4. Sling ladder (4), remove mounting bolts, and

then remove the ladder.
4 Ladder:
75 kg
10. Disconnect tubes (14), (15), and (16).
12. Disconnect tube (20) at the intermediate

connection.
50-284 WA1200-6
Hydraulic system
Removal and installation of hydraulic tank, filter case assembly
13. Sling the hydraulic tank and filter case assembly Installation 50-285
(21), remove mounting bolts (22), and then
remove the hydraulic tank and filter case q perform installation in the reverse order to the re-
assembly. [*1] moval.
4 Hydraulic tank and filter case assem-
bly: [*1]
1,370 kg 3 Hydraulic tank mounting bolt:
824 to 1,030 Nm {84 to 105 kgm}
q Flushing hydraulic circuit

flush the hydraulic circuit by referring to
steering hydraulic circuit".

filler port to the specified level. Run the engine to
circulate the oil through the system. Then check
the oil level again.
q Air bleeding
Bleed air from the hydraulic circuit. For details,
see "Bleeding air from work equipment hydraulic
circuit and steering hydraulic circuit".
WA1200-6 50-285
Hydraulic system
Removal and installation of No. 1 work equipment pump assembly
Removal and installation of No. 1 work equipment pump assembly 50-286
Removal 50-286 4. Remove U-bolt (8).

ment "2. Preparatory work" and "3. Precau- 5. Disconnect suction tube (9).

6 Hydraulic oil:
approx. 1,125 l
2. Open the upper step cover and remove step (1).
7. Sling work equipment pump assembly (12),

remove mounting bolts, and then remove the
work equipment pump assembly. [*1]
4 Work equipment pump assembly:
195 kg
3. Disconnect hoses (2), (3), (4), (5), and (6).
50-286 WA1200-6
Hydraulic system
Installation 50-287
q perform installation in the reverse order to the re-

moval.
[*1]
3 Pump assembly mounting bolt:
455 to 565 Nm {46.5 to 58 kgm}

flush the hydraulic circuit by referring to
steering hydraulic circuit".

filler to the specified level. Run the engine to
q Air bleeding
WA1200-6 50-287
Hydraulic system
Removal and installation of No. 2 work equipment pump assembly 50-28


2. Open the upper step cover. q Flushing hydraulic circuit

3. Disconnect hoses (1), (2), (3), (4), and (5). flush the hydraulic circuit by referring to
4. Remove pump outlet hoses (6), (7), and (8). steering hydraulic circuit".
5. Disconnect suction tubes (9) and (10). q Refilling with oil (hydraulic tank)
6. Sling work equipment pump assembly (11), filler to the specified level. Run the engine to
remove mounting bolts, and then remove the circulate the oil through the system. Then, check
work equipment pump assembly. [*1] the oil level again.
4 Work equipment pump assembly:
180 kg q Air bleeding
50-288 WA1200-6
Hydraulic system
Removal and installation of switch pump assembly
Removal and installation of switch pump assembly 50-289


2. Open the upper step cover. q Flushing procedure for hydraulic circuit
3. Disconnect hoses (1) and (2). flush the hydraulic circuit by referring to
4. Disconnect hoses (3) and (4). steering hydraulic circuit".
5. Remove hose and disconnect suction tube (6). q Refilling with oil (hydraulic tank)
6. Disconnect hose (7). filler to the specified level. Run the engine to
7. Disconnect hoses (8) and (9). the oil level again.
8. Sling the switch pump assembly, remove q Air bleeding

mounting bolts, and then remove the switch Bleed air from the piston pump and work equip-
pump assembly. [*1] ment hydraulic circuit. For details, see "Bleeding
4 Switch pump assembly: air from piston pump" and "Bleeding air from
250 kg work equipment hydraulic circuit and steering
hydraulic circuit".
WA1200-6 50-289
Hydraulic system
Removal and installation of work equipment control valve assembly
Removal and installation of work equipment control valve assembly 50-290
Preparation work
1. Before starting maintenance work, measure the raising speed of the work equipment.
a Work equipment control valve check sheet

Machine Serial No.:
Standard value
Replacement of control valve
1,900 rpm
Before After
Specifications New machine
Low idle 650 ± 25
High idle 1,900 ± 50
Engine Work equipment circuit
1,750 to 1,950
(rpm) relieved
At torque converter stall 1,750 to 1,950
Full stall 1,600 to 2,000
Work equipment Lift arm Raise 13.5 ± 0.5
speed Lift arm Lower 5.3 ± 0.5
(High idle) Bucket Tilt (on ground) 4.1 ± 0.3
(sec) Bucket dump (no load) 2.7 ± 0.3
50-290 WA1200-6
Hydraulic system
2. Clean around the control valve. Removal 50-291

Around cover
a Place a large oil pan under the front frame.
(A large amount of oil flows out when hoses
and tubes are disconnected or removed.)
6 Hydraulic oil:
1,125 l
2. Remove front cover (1) on the front frame.

[*1]
4 Cover:
21 kg
Around the control valve and piping
k Before performing removal, be sure to im-

plement "2. Preparatory work" and "3.
Precautions during work" in "00 Safety
notice".
q Perform the following work before stopping
the engine.
k Raise the lift arm and place it on lift arm
support [1].
k Set ladder [2].
WA1200-6 50-291
Hydraulic system
3. Remove the front work equipment control valve a When removing hoses and tubes, be
assembly according to the following procedure. careful not to let dirt or dust enter the
1) Remove tubes (2), (3), (4), (5), (6), and (7). tubes.
a Do not reuse the removed O-rings but re- a Place the bolts and washers in a plastic
place them with new ones. bag and keep it with the tube.
2) Remove hoses (8), (9), (10), and (11). a Cover the ends of the removed tubes with
a Do not reuse elbows, unions, and O-rings pieces of plastic sheet, as the tubes are
but replace them with new ones, to pre- reused.
vent incorrect assembly. a Do not plug the tube openings with wood
3) Remove three mounting bolts for front work or cork pieces.
equipment control valve assembly (12). (Their particles may enter and cause
serious problems.)
a Before removing hoses and tubes, put

numbers (N) on the control valve, and 4) Install lifting tool.
hoses and tubes to indicate their installed a Eyebolt size: M12 x 1.75
positions. 5) Lift and remove front work equipment control
valve assembly (12).
4 Front work equipment control valve
assembly:
95 kg
50-292 WA1200-6
Hydraulic system
4. Remove the center work equipment control a When removing hoses and tubes, be
valve assembly according to the following proce- careful not to let dirt or dust enter the
dure. tubes.
1) Remove tubes (13), (14), (15), (16), (17), and a Place the bolts and washers in a plastic
(18). bag and keep it with the tube.
a Do not reuse the removed O-rings but re- a Cover the ends of the removed tubes with
place them with new ones. pieces of plastic sheet, as the tubes are
2) Remove hoses (19), (20), (21), and (22). reused.
a Do not reuse elbows, unions, and O-rings a Do not plug the tube openings with wood
but replace them with new ones, to pre- or cork pieces.
vent incorrect assembly. (Their particles may enter and cause
3) Remove three mounting bolts for center work serious problems.)
equipment control valve assembly (23).
4) Install lifting tool.

a Before removing hoses and tubes, put a Eyebolt size: M12 x 1.75
numbers (N) on the control valve, and 5) Lift and remove center work equipment
hoses and tubes to indicate the installed control valve assembly (23).
positions. 4 Center work equipment control valve
assembly:
95 kg
WA1200-6 50-293
Hydraulic system
5. Remove the rear work equipment control valve a When removing hoses and tubes, be
assembly according to the following procedure. careful not to let dirt or dust enter the
1) Remove tubes (24), (25), (26), (27), (28), and tubes.
(29). a Place the bolts and washers in a vinyl bag
a Do not reuse the removed O-rings but re- and keep it with the tube.
place them with new ones. a Cover the ends of the removed tubes with
2) Remove hoses (30), (31), and (32). pieces of plastic sheet, as the tubes are
a Do not reuse elbows, unions, and O-rings reused.
but replace them with new ones, to pre- a Do not plug the tube openings with wood
vent incorrect assembly. or cork pieces.
3) Remove three mounting bolts for rear work (Their particles may enter and cause
equipment control valve assembly (33). serious problems.)
a Before removing hoses and tubes, put 4) Install lifting tool.

numbers (N) on the control valve, and a Eyebolt size: M12 x 1.75
hoses and tubes to indicate the installed 5) Lift and remove rear work equipment control
positions. valve assembly (33).
4 Rear work equipment control valve as-
sembly:
95 kg
50-294 WA1200-6
Hydraulic system
6. Remove two bracket mounting bolts and remove

bracket (34).
4 Work equipment control valve mount-
ing bracket:
45 kg
WA1200-6 50-295
Hydraulic system
Installation 50-296 a Do not reuse deteriorated rubbers or elbows,

unions, hoses smeared with oil as shown be-
a Do not reuse control valve, PPC piping (hose, el- low.
bow, nipple), cushion, plate insulator, bolts, and
washers, but replace them with new ones.
1. Plug the PPC piping.
50-296 WA1200-6
Hydraulic system
2. Clean the inside of front frame with detergent. 4. Install rear work equipment control valve
assembly, center work equipment control valve
3. Install bracket (34) according to the following assembly, and front work equipment control
procedure. valve assembly to the bracket in this order.
1) Place two cushions at the mounting part on 3 Control valve mounting bolt:
front frame (36). 235 to 285 Nm {23.5 to 28.5 kgm}
2) Place bracket (34) on the cushion while
aligning mounting bolt holes.
4 Bracket:
45 kg
3) Install cushions (37), (38) and (39), and
washers (40), and fasten them with four
3 Mounting bolt:
235 to 285 Nm {23.5 to 28.5 kgm}
WA1200-6 50-297
Hydraulic system
5. Install hoses and tubes according to the following procedure.

1) Installation of hoses and tubes (1)
50-298 WA1200-6
Hydraulic system
WA1200-6 50-299
Hydraulic system
5) Installation of pilot hose

1] Connect the hose.
2] Adjust the angle of elbow so that it does not interfere with other parts or twists.
50-300 WA1200-6
Hydraulic system
WA1200-6 50-301
Hydraulic system
6) Installation of pilot hose (installation of clamp)
50-302 WA1200-6
Hydraulic system
q Perform the subsequent installation in the re-

verse order to the removal.
[*1]
a Replace all the mounting bolts, washers, and
spacers for front cover (1) with new ones.
4 Front cover:
21 kg

When repairing the valve that is internally
damaged, flush the hydraulic circuits. For
details, see "Flushing procedure for work equip-
ment and steering hydraulic circuit".

filler port to the specified level. Run the engine to
circulate the oil through the system. Then check
q Air bleeding
WA1200-6 50-303
Work equipment
Removal and installation of bucket cylinder assembly

Removal and installation of bucket cylinder assembly 50-304
Special tools 50-304
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name Detail of work, remarks
bol
SMT-890-5480 Forcing bolt q 2 Q Removal of work equipment pin (for f180

1
SMT-890-5491 Flanged nut q 2 Q mm)
3 SMT-890-5330 q Flange nut q 1 Q Installation of work equipment pin
T SMT-890-5350 q Leveling pad q 1 Q
SMT-890-5370 q Adapter (for 24 mm) q 2 Q
SMT-890-5050 Plate q 1 Q
4 Removal of collar (for f180 and f240 mm)
SMT-890-5070 Bolt q 4 Q
10 42C-98-11320 Plate q 1 Q Collar stopper plate (for f180 mm)
13 01017-51245 Bolt q 2 Collar tap bolt
14 01010-81230 Bolt q 2 Collar stopper plate tap bolt
15 42C-98-11350 Plate q 1 Q Fixing plate for press fit of bushing
How to use special tools 50-304

1. How to use work equipment pin removal tool 2) Through clearance (a) made in Step 1),
(T1) install the flanged nut of tool T1 (T1-2) into
a Use removal tool T1 to remove the work the flange hole of pin (10).
equipment mounting pin.
1) Push pin (10) approximately 40 mm from the
cover side of the pin to make clearance (a) on
the flange side of the pin.
50-304 WA1200-6
Work equipment
3) Screw in forcing bolt (T1-1) of tool T1 into 1) Install the plate of T4. Since the plate can be
flanged nut (T1-2) installed in Step 2) to used for both pins of f180 and 240 mm in
remove pin (10). diameter, use the bolt hole appropriate for
the pin.
2. How to use collar removal tool (T4)

a If the collar is hard to remove, use collar re- 2) Install four bolts (M12, L = 50 mm) in bolt
moval tool T4. holes (a) to secure the plate (T4-1) of tool T4
a Select the bolt hole in the plate of the tool ac- to collar A (11) or collar B (12).
cording to the pin diameter. a Use the collar forcing tap hole and use the
Reference: Tool T4 can be used for both pin washer, too.
diameters f180 mm and f240 mm. 3) Tighten forcing bolt (T4-2) of tool T4 to
a As the diameter of pins at the piston rod and remove collar A (11) or collar B (12).
cylinder bottom of the bucket cylinder is f180
mm, use the f180 mm hole.
q Pin diameter A: f180
B: f240
C: f280
(Reference: Tool T5 is for f280 pin.)
WA1200-6 50-305
Work equipment
3. How to use the work equipment pin insertion tool 4. How to install collar stopper plates (T10, T13,
(T3) and T14)
a Use tool T3 to insert the work equipment pin. a The collar stopper plates T10, T11 and T12,
1) Assemble tool T3. and bolts T13 and T14 are provided for each
a For details, see T3 (SMT-890-5300) in machine as standard attached tools.
"Sketches of special tools". a For part numbers of tools T11 and T12, see
a Tool T3, has adapters (SMT-890-5370) "Special tool list".
for 24-mm bolt hole and (SMT-890-5360) a Use tool T10, T11 or T12 depending on the
for 30-mm bolt hole. Use adapter diameter of the mounting pin.
SMT-890-5370 for 24-mm bolt hole. Tool T10: For pin of f180 mm
Tool T11: For pin of f240 mm
a Tool T14 bolt is provided being installed to
the collar stopper plates T10, T11 and T12 as
a dummy bolt. Tool T14 is used not only as
the collar stopper plate tap bolt but also for
rust prevention of the bolt hole. Be sure to in-
stall it to the bolt hole again after it is used to
install the pin.
a Remove tool T14 bolt installed to tool T10,
T11 or T12, then use it to fix the collar stop-
per plate T10, T11 or T12.
a Tool T13 is used as the collar tap bolt.
a Three types of approaches A, B and C are
available for installing the collar stopper
2) Insert tool guide bar (T3-2) into the flange
plates T10, T11 and T12.
bolt hole of pin (10), then install tool adapter
(T3-6) to the pin flange mounting bolt hole.
A type: When female threads for fixing the collar
stopper plate are cut in the seat
3) Screw in tool bolt (T3-4) to insert pin (10).
q Joint between lift arm and bell crank
a Do not use an impact wrench but use a
(240-mm pin)
socket wrench to tighten the bolt.
q Joint between lift cylinder bottom and
a To prevent the bushing seal assembly in-
front frame (240-mm pin)
stalled to the collar from coming off, never
q Joint between lift arm and front frame
hit the pin with a hammer to insert it.
(280-mm pin)
q Joint between lift arm and piston rod of lift
cylinder (240-mm pin)
q Joint between bucket cylinder bottom and
front frame (180-mm pin)
50-306 WA1200-6
Work equipment
11. Collar A C type: When a dirt intrusion prevention ring

11A. Collar boss on pin flange side screw is used for securing the collar
12. Collar B stopper plate.
12A. Collar boss on pin tip side a In this case, install snap ring (22) or (27),
Reference: The portion to which the collar then install dirt intrusion prevention ring
is installed is referred to as "collar (21) or (26).
boss". a For C type, use the ring horizontalizing bolt
(24) or (28) as the fixing bolt of tool T10, T11
or T12.
q Joint between bell crank and bucket link
(180-mm pin)
q Joint between lift arm and bucket
(240-mm pin)
q Joint between bucket and bucket link
(180-mm pin)
11. Collar A
11A. Collar boss on pin flange side
12. Collar B
12A. Collar boss on pin tip side
21. Ring (dirt intrusion prevention ring)
(*1)
22. Snap ring (*1)
B type: When female threads for fixing the collar
24. Bolt (ring horizontalization bolt) (*1)
stopper plate are cut directly in collar
26. Ring (dirt intrusion prevention ring)
boss (12A).
(*2)
q Joint between bell crank and piston rod
27. Snap ring (*2)
bucket cylinder (180-mm pin)
11. Collar A
(*1): Joint between lift arm and bucket
(*2): Joint between bucket link and
12. Collar B
bucket, and joint between bucket
link and bell crank
WA1200-6 50-307
Work equipment
Features of work equipment connecting part 50-308 q Clearance without tension: 5.1 mm
1. Lubrication of work equipment joints Lubricated q Appropriate clearance after shim adjustment:
type work equipment pins and bushings are 0.5 to 0.7 mm
employed for lubricating the work equipment
joints.
2. In order to prevent leakage of oil, the bushing
seal assembly and O-ring are installed to the
contact portions between the parts to provide the
sealing function.
3. Bushing seal assembly (14) is provided with
tension enough to secure the sealing perfor-
mance.
4. To give bushing seal assembly (14) required
tension, shims are installed to each part of work
equipment pin, collar A (11) and collar B (12).
5. Work equipment joint parts must be installed so
that an appropriate clearance is secured
between bushing (13) and collar A (11), and
between bushing (13) and collar B (12) to
provide bushing seal assembly (14) with enough
tension.
50-308 WA1200-6
Work equipment
Preparation of work foothold (reference) 50-309 2. Installing work foothold [1]

Before removing the bucket cylinder, take the fol- 1) Place work foothold [1] to its installed posi-
lowing steps to install work foothold [1]. tion on the bucket and lift arms.
1. Assembling work foothold [1] a Position the end of stand [1-8] above the
1) Install deck plates [1-9] to [1-13] on deck [1-2] level part of the bucket top.
with bolts. a Position the other end above the lift arms.
2) Sling deck [1-2], install stand [1-8] to it with 2) Secure right and left legs [R] to bucket [B] by
bolts. means of spot welding.
3) Place right and left stays [1-15] on the lift
arms.
a Position them so that they contact deck
[1-2] at their middle parts.
4) Secure deck [1-2] to right and left stays [1-15]
by means of spot welding.
WA1200-6 50-309
Work equipment
General view after installation Removal 50-310

k Since oil is contained in the mounting pin,
prepare a container to receive the oil and
drain the oil from the oil drain plug on the
flange side of the mounting pin.
1. Removal of pin connecting bell crank and piston

rod of bucket cylinder
1) Sling bucket cylinder assembly (6).
4 Bucket cylinder assembly:
1,400 kg
2) Remove mounting bolts (17) and four

washers (18) of cover (19) installed to
mounting pin (10) connecting bell crank (2)
and piston rod (6) of the bucket cylinder, and
remove the cover.
a When the cover is hard to remove, use
the forcing tap of the cover.
a Prepare an oil container since the oil in
the mounting pin flows out when the cov-
er is removed.
3) Remove four pin flange fixing bolts (8) and

four spacers (9) of mounting pin (10), pull out
mounting pin (10) using special tool T1, and
disconnect piston rod (6) of the bucket
cylinder from bell crank (2).
50-310 WA1200-6
Work equipment
4 Mounting pin: a Dust seal (15) is installed to the machines

70 kg with serial number 50077 and up.
a For the mounting pin removal procedure,
see "1. How to use work equipment pin
removal tool (T1)" in the "How to use spe-
cial tools".
7) Taking the same procedures in Steps 1) to

6), remove the other mounting pin
connecting the bell crank and piston rod of
the bucket cylinder.
4) Start the engine and retract the piston rod of
bucket cylinder. 2. Wiring harness connector
k After retracting the piston rod, stop q Disconnect harness connector F13 (42).
the engine, loosen the hydraulic tank
oil filler cap to release pressure inside 3. Hose
the tank. Then operate the work equip- q Disconnect hoses (43) and (44).
ment control lever two or three times
to release the remaining pressure in
the piping.
5) Remove collar A (11) and collar B (12) from
bell crank (2).
q Length of collar A (11) and collar B (12):
91.3 mm
a If collars A and B are hard to remove, use
special tool T4 to remove them.
a For the collars A and B removal proce-
dure using special tool T4, see "2. How to
use collar removal tool (T4)" in the "How
to use special tools".
4. Removal of pin connecting front frame and

bucket cylinder
mounting pin (10) connecting front frame (7)
and cylinder bottom (6) of the bucket
cylinder, and remove the cover.
er is removed.
6) Remove bushing seal assembly (14), dust

seal (15) and collar O-ring (16) from collar A
(11) and collar B (12).
WA1200-6 50-311
Workequipment
2) Remove pin flange fixing bolts (8) and four 4) Remove bushing seal assembly (14), dust
spacers (9) of mounting pin (10), pull out seal (15) and collar O-ring (16) from collar A
mounting pin (10) using special tool T1, and (11) and collar B (12).
disconnect cylinder bottom (6) of the bucket
cylinder from front frame (7).
k Check that the bucket cylinder assem-
bly is slung securely, and then pull out
the mounting pin.
4 Mounting pin:
70 kg
see “1. How to use work equipment pin
removal tool" in the "How to use special
tools".

connecting the front frame and cylinder
bottom of the bucket cylinder.
5. Bucket cylinder assembly

q Sling bucket cylinder assembly (6) and re-
move it.
4 Bucket cylinder assembly (one unit):
1,400 kg
front frame (7).
a Length of collar
q Collar A (11) and collar B (12): 109.3
mm
use collar removal tool" in the "How to use
special tools".
50-312 WA1200-6
Work equipment
6. Removal of the bushing press fitted to the Outline of shim selection for installing mounting
cylinder pin (Outline of shim adjustment procedure) 50-313
q When replacing bushing (13) press fitted to q Outline of shim adjustment
the cylinder bottom and piston rod, gas cut a At the final stage of assembling the work
bushing (13) at four places to remove it. equipment, provide a clearance of 0.5 to 0.7
a Take care not to melt bushing boss (13A) mm between bushing (13) and collar A (11),
in gas cutting. and between bushing (13) and collar B (12).
Reference: The portion to which the bushing
is press fitted is referred to as "bushing
boss".
a At the final stage of assembling the work

equipment, use shims to adjust the clearance
between bushing (13) and collar A (11) and
collar B (12) with seal assembly (14), that is
5.1 mm when no shims are fitted, to 0.5 to 0.7
mm.
a For the subsequent procedure, see "Outline

of shim selection for installing mounting pin
(Outline of shim adjustment procedure)" in
"Removal and installation of work equipment
assembly".
WA1200-6 50-313
Work equipment
Installation 50-314
a Install the bucket cylinder assembly. For details,
see "Installation" of "Removal and installation of
work equipment assembly"
q Refilling
a Start the engine, circulate hydraulic oil in hy-
draulic cylinder, piping, and hoses, and sup-
ply oil through the hydraulic tank oil filler to
the specified level.

When repairing the cylinder that is internally
q Air bleeding
see "Bleeding air from work equipment circuit
and steering circuit".
q Running in
a Perform running-in operation. For details,
see "Procedure for running in bucket pin".
50-314 WA1200-6
Work equipment
Removal and installation of lift cylinder assembly
Removal and installation of lift cylinder assembly 50-315
Special tools 50-315
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name Detail of work, remarks
bol
L1 793T-870-1410 stand q 1 Q Support for front frame

SMT-890-5460 Forcing bolt q 2 Q Removal of work equipment pin (for f240
2
SMT-890-5471 Flanged nut q 2 Q and 280 mm)
3 SMT-890-5330 q Flange nut q 1 Q Installation of work equipment pin
T
SMT-890-5350 q Leveling pad q 1 Q
SMT-890-5360 q Adapter (for 30 mm) q 2 Q
4 Removal of collar (for f180 and 240 mm)
SMT-890-5070 Bolt q 4 Q
11 42C-98-11330 Plate q 1 Q Collar stopper plate (for f240 mm)
13 01017-51245 Bolt q 2 Collar tap bolt
14 01010-81230 Bolt q 2 Collar stopper plate tap bolt
15 42C-98-11350 Plate q 1 Q Fixing plate for press fit of bushing
How to use special tools 50-315

1. How to use work equipment pin removal tool 2) Through clearance (a) made in Step 1),
(T2) install the flanged nut of tool T2 (T2-2) into
a Use removal tool T2 to remove the work the flange hole of pin (10).
equipment mounting pin.
WA1200-6 50-315
Work equipment
3) Screw in forcing bolt (T2-2) of tool T2 into 1) Install the plate of T4. Since the plate can be
flanged nut (T2-1) installed in Step 2) to used for both pins of f180 and 240 mm, use
remove pin (10). the bolt hole appropriate for the pin.
2. How to use collar removal tool (T4) 2) Install four bolts (M12, L = 50 mm) in bolt
a If the collar is hard to remove, use collar re- holes (a) to secure the plate (T4-1) of tool T4
moval tool T4. to collar A (11) or collar B (12).
a Select bolt hole in the plate of the tool accord- a Use the collar forcing tap hole and use the
ing to the pin diameter. washer, too.
Reference: Tool T4 can be used for both pin 3) Tighten forcing bolt (T4-2) of tool T4 to
diameters f180 mm and f240 mm. remove collar A (11) or collar B (12).
a As the diameter of pins at the piston rod and
cylinder bottom of the lift arm cylinder is f240
mm, use the f240 mm hole.
q Pin diameter A: f180
B: f240
C: f280
(Note: (Reference: Tool T5 is for f280 pin.)
50-316 WA1200-6
Work equipment
3. How to use the work equipment pin insertion tool 4. How to install collar stopper plates (T11, T13,
(T3) and T14)
a Use tool T3 to insert the work equipment pin. a The collar stopper plates T10, T11 and T12,
1) Assemble tool T3. and bolts T13 and T14 are provided for each
a For details, see T3 (SMT-890-5300) in machine as standard attached tools.
"Sketches of special tools". a For part numbers of tools T10 and T12, see
a Tool T3 has adapters (SMT-890-5370) for "Special tools list".
24-mm bolt hole and (SMT-890-5360) for a Use tool T10, T11 or T12 depending on the
30-mm bolt hole. Use adapter diameter of the mounting pin.
SMT-890-5360 for 30-mm bolt hole. Tool T10: For pin of f180 mm
install the pin.
2) Insert guide bar (T3-2) into the flange bolt
hole of pin (10), then install adapter (T3-6) to
the pin flange mounting bolt hole.
3) Screw in tool bolt (T3-4) and insert pin (10).
a Do not use an impact wrench but use a
socket wrench to tighten the bolt.
a To prevent the bushing seal assembly in-
stalled to the collar from coming off, never
hit the pin with a hammer to insert it.
WA1200-6 50-317
Work equipment
A type: When female threads for fixing the collar C type: When female threads for fixing the collar
stopper plate are cut in the seat stopper plate are cut in the dust intrusion
q Joint between lift arm and bell crank prevention ring
(240-mm pin) a In this case, install snap ring (22) or (27),
q Joint between lift cylinder bottom and front then install dirt intrusion prevention ring (21)
frame (240-mm pin) or (26).
q Joint between lift arm and front frame a For C type, use the ring horizontalizing bolt (24)
(280-mm pin) or (28) as the fixing bolt of tool T10, T11 or T12.
q Joint between lift arm and piston rod of lift q Joint between bell crank and bucket link
arm cylinder (240-mm pin) (180-mm pin)
q Joint between bucket cylinder bottom and q Joint between lift arm and bucket (240-mm
front frame (180-mm pin) pin)
11. Collar A q Joint between bucket and bucket link
11A. Collar boss on pin flange side (180-mm pin)
12. Collar B 11. Collar A
12A. Collar boss on pin tip side 11A. Collar boss on pin flange side
Reference: The portion to which the collar is 12. Collar B
installed is referred to as "collar boss". 12A. Collar boss on pin tip side
21. Ring (dirt intrusion prevention ring) (*1)
22. Snap ring (*1)
27. Snap ring (*2)
(*2): Joint between bucket link and bucket,
and joint between bucket link and bell
crank
B type: When the collar stopper plate fixing screw

hole is drilled directly on collar boss
(12A).
q Joint between bell crank and piston rod buck-
et cylinder (180-mm pin)
11. Collar A
12. Collar B
50-318 WA1200-6
Work equipment
Features of work equipment connecting part 50-319 4. To give bushing seal assembly (14) required
1. Lubrication of work equipment joints tension, shims are installed to each part of work
Lubricated type work equipment pins and bush- equipment pin, collar A (11) and collar B (12).
ings are employed for lubricating the work equip- 5. Work equipment joint parts must be installed so
ment joints. that an appropriate clearance is secured
2. In order to prevent leakage of oil, the bushing between bushing (13) and collar A (11), and
seal assembly and O-ring are installed to the between bushing (13) and collar B (12) to
contact portions between the parts to provide the provide bushing seal assembly (14) with enough
sealing function. tension.
3. Bushing seal assembly (14) is provided with q Clearance without tension: 5.1 mm
tension enough to secure the sealing perfor- q Appropriate clearance after shim adjustment:
mance. 0.5 to 0.7 mm
WA1200-6 50-319
Work equipment
Removal 50-320 2) Install foothold [3] on the front of the front

k Before performing removal, be sure to imple- support.
k Stop the machine on a level ground, lower
the bucket to the ground, apply the parking
brake, and then lock the tires with chocks.
k Since oil is contained in the mounting pin,
prepare a container to receive the oil and
drain the oil from the oil drain plug on the
flange side of the mounting pin.
[If tires are not removed] 50-320

1. Sling front fender (42) and remove it.
4 Front fender:
140 kg
3) Install foothold [4] outside of the tire.
2. Preparation of work foothold

1) Raise the lift arm and place it on lift arm stand
[2].
3. Removal of pin connecting lift arm and piston rod

of lift arm cylinder
1) Sling lift arm cylinder assembly (5).
4 Lift arm cylinder assembly:
2,950 kg
50-320 WA1200-6
Work equipment
3) Remove pin flange fixing bolts (8) and four

spacers (9) of mounting pin (10), then pull out
mounting pin (10) using special tool T2.
4 Mounting pin:
140 kg
tools".
2) Remove mounting bolts (17) and washers

(18) of cover (19) installed to mounting pin
(10) connecting lift arm (1) and piston rod (5)
of the lift arm cylinder, and remove the cover.
er is removed.
4) After removing mounting pin (10), place
blocks [1] between lift arm cylinder (5) and
front axle (35) to fix lift arm cylinder (5).
WA1200-6 50-321
Work equipment
5) Start the engine and retract the piston rod of 8) Disconnect hoses (43) and (44).
lift arm cylinder.
k After retracting the piston rod, stop
oil filler cap to release pressure inside
the tank. Then operate the work equip-
the piping.
lift arm (1).
101.8 mm
a For the collars A and B removal proce- 9) Taking the same procedures in Steps 1) to
dure using special tool T4, see "2. How to 8), remove the other mounting pin
use collar removal tool" in the "How to use connecting the lift arm and piston rod of the
special tools". lift arm cylinder.
4. Removal of pin connecting front frame and lift

arm cylinder bottom
(10) connecting front frame (7) and cylinder
bottom (5) of the lift arm cylinder, and remove
the cover.
er is removed.

50-322 WA1200-6
Work equipment
2) Remove pin flange fixing bolts (8) and four 4) Remove bushing seal assembly (14), dust
spacers (9) of mounting pin (10), then pull out seal (15) and collar O-ring (16) from collar A
mounting pin (10) using special tool T2. (11) and collar B (12).
4 Mounting pin:
140 kg
tools".

connecting the lift arm and lift arm cylinder
bottom.
5. Lift arm cylinder assembly

3) Remove collar A (11) and collar B (12) from q Sling lift arm cylinder assembly (5) and re-
front frame (7). move it.
a Length of collar 4 Lift arm cylinder assembly:
q Collar A (11): 183.3 mm (Outside of 2,950 kg
the machine)
q Collar B (12): 121.8 mm (Inside of the
machine)
special tools".
a The collar length differs between those to
be installed on the outside and inside of
the machine. Take care not to install
wrong collar.
WA1200-6 50-323
Work equipment
6. Removal of the bushing press fitted to the [If tires are removed] 50-324
cylinder 1. Preparation of work foothold
q When replacing bushing (13) press fitted to 1) Lift up the front frame and set tool L1.
the cylinder bottom and piston rod, gas cut
bushing (13) at four places to remove it.
a Take care not to melt bushing boss (13A)
in gas cutting.
boss".
2) Raise the lift arm and place it on lift arm stand

[1].
3) Install foothold [2] on the front of the front

support.
50-324 WA1200-6
Work equipment
4) Remove front fender (2) and tire (3).

k When removing front fender (2) and
tire (3), be sure to use portable ladder
[3] or build a foothold.

1) Sling arm lift arm cylinder assembly (5).
2,950 kg

4 Mounting pin:
140 kg
removal tool" in the How to use special
tools "How to use special tools".

(10) connecting lift arm (1) and piston rod (5)
of the lift arm cylinder, and remove the cover.
er is removed.
WA1200-6 50-325
Work equipment
4) Start the engine and retract the piston rod of 7) Disconnect hoses (43) and (44).
lift arm cylinder.
k After retracting the piston rod, stop
oil filler cap to release pressure inside
the tank. Then operate the work equip-
the piping.
lift arm (1).
101.8 mm
a For the collars A and B removal proce- 3. Removal of pin connecting front frame and lift
dure using special tool T4, see "2. How to arm cylinder bottom
use collar removal tool" in the "How to use 1) Remove mounting bolts (17) and washers
special tools". (18) of cover (19) installed to mounting pin
(10) connecting front frame (7) and cylinder
bottom (5) of the lift arm cylinder, and remove
the cover.
er is removed.

a Dust seal (15) is installed to the machine
with serial number 50077 and up.

4 Mounting pin:
140 kg
tools".
50-326 WA1200-6
Work equipment
3) Remove collar A (11) and collar B (12) from 4. Lift arm cylinder assembly
front frame (7). q Sling lift arm cylinder assembly (5) and re-
a Length of collar move it.
q Collar A (11): 183.3 mm (Outside of 4 Lift arm cylinder assembly:
the machine) 2,950 kg
q Collar B (12): 121.8 mm (Inside of the
machine)
special tools".
a The collar length differs between those to
be installed on the outside and inside of
the machine. Take care not to install
wrong collar.
5. Removal of the bushing press fitted to the

cylinder
q When replacing bushing (13) press fitted to
the cylinder bottom and piston rod, gas cut
a Take care not to melt bushing boss (13A) in
gas cutting.
Reference: The portion to which the bushing is
press fitted is referred to as "bushing
boss".

WA1200-6 50-327
Work equipment
Outline of shim selection for installing mounting Installation 50-328

pin (Outline of shim adjustment procedure) 50-328 a Install the lift arm cylinder assembly. For details,
q Outline of shim adjustment see "Installation" of "Removal and installation of
a At the final stage of assembling the work work equipment assembly".
equipment, provide a clearance of 0.5 to 0.7
mm between bushing (13) and collar A (11), q Refilling
and between bushing (13) and collar B (12). a Start the engine, circulate hydraulic oil in hy-
draulic cylinder, piping, and hoses, and sup-
ply oil through the hydraulic tank oil filler to

When repairing the cylinder that is internally
q Air bleeding
q Running in
see "Procedure for running in lift arm pin".
mm.
a For the subsequent procedure, see "Outline

of shim selection for installing mounting pin
(Outline of shim adjustment procedure)" in
"Removal and installation of work equipment
assembly".
50-328 WA1200-6
Work equipment
Disassembly and assembly of work equipment cylinder
Disassembly and assembly of work equipment cylinder 50-329
Special tools 50-329 2) Remove mounting bolts (3) of head cover (2).
New/redesign
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
2 790-502-1003 Cylinder repair stand q 1

3 790-720-1000 Expander q 1
796-720-1720 Ring q 1
U 07281-02429 Clamp q 1
4
796-720-1730 Ring q 1
07281-03209 Clamp q 1
5 790-102-3902 Wrench q 1
Disassembly 50-329
3) Pull out piston rod (4) from the cylinder.
1. Cylinder assembly
a As remaining oil inside the cylinder flows
1) Set cylinder assembly (1) to tool U2.
4 Steering cylinder:
out when pulling out the rod, prepare an
oil container.
600 kg
a If the piston rod is hard to be pulled out
4 Bucket cylinder:
from the cylinder, slightly turn the piston
1,400 kg
4
rod and pull the cylinder.
Lift arm cylinder:
3,000 kg
WA1200-6 50-329
Work equipment
2. Piston rod q Bucket cylinder and lift arm cylinder

q Steering cylinder 1) Remove mounting bolts (5) and remove
1) Remove lock screw (31) of piston assembly spacer (6).
(30). 2) Pull out piston (7) and cylinder head (2) from
q Screw size: M12 x pitch 1.75 piston rod (4).
3) Remove two backup rings (8) and O-ring (9)
from piston rod (4).
a If screw (31) cannot be removed because

it is punched too tight, screw in it deeply
into the hole once, tap the hole by using 3. Piston
tap [1], then remove the screw. 1) Remove wear rings (10) from piston (7).
2) Remove piston ring (11).
2) Using tool U5, remove piston assembly (30)

from piston rod (32).
3) Remove two backup rings (18) and O-ring
(19) from piston assembly (30).
4) Remove cylinder head (2).
50-330 WA1200-6
Work equipment
4. Head cover Assembly 50-3 1

1) Remove O-ring (19) and backup rings (20) a Clean each part, and when installing the U-pack-
from head cover (2) . ing, dust seal, and O-ring, take care not to dam-
2) Remove bolt (21) and spacer (22). age them.
3) Remove seals (23) and (24), collar (25), and 1. Head cover
seals (26) and (27) from spacer (22). 1) Press fit bushing (36) to head cover (2) and
4) Remove rod packing (28) and buffer ring install snap ring (35).
(29). 2) Install buffer ring (29) and rod packing (28).
5) Remove snap ring (35) and bushing (36) 3) install seals (27) and (26), collar (25), and
from head cover (2). seals (24) and (23) to spacer (22).
4) Install spacer (22) and tighten bolt (21).
5) Install backup ring (20) and O-ring (19) to
head cover (2).
a Do not try to force the backup ring into po-
sition. Warm it in warm water approxi-
mately 50 to 60 °C before fitting it.
WA1200-6 50-331
Work equipment
2. Piston 3. Piston rod

1) Set piston ring (11) to tool U3 and expand it. q Steering cylinder
a Set the piston ring to the tool, and then ro- 1) Install head cover (2) to cylinder rod (32).
tate the handle eight to ten times to ex- 2) Install two backup rings (8) and O-ring (9) to
pand the ring. piston (30).
a Do not try to force the backup ring into po-
sition. Warm it in warm water at approx.
50 to 60 °C before fitting it.
2) Remove piston ring (11) from tool U3, and

install the ring to piston (7).
3) Using tool U4, compress piston ring (11).
3) When reusing piston rod (32) and piston
assembly (30), install them according to the
a Remove any flash or burr on the threaded
portion by using a file or other tool.
a Wash thoroughly and remove all metal
particles and dirt.
1] Screw piston assembly (30) onto piston
rod (32) by using tool U5, and tighten the
piston assembly until the tapped holes
are aligned.
2] Install screw (31) to piston (30).
a Install the screw after degreasing and
drying the threads completely.
a After installing the screw, punch it at
4) Install wear rings (10) to piston (7).
four points on its periphery.
2 Threaded portion of screw:
Adhesive (Loctite No.262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
a After tightening the screw, punch it at
a After tightening the screw, check that
unfastening torque is 41.2 to 88.2 Nm
{4.2 to 9 kgm}.
50-332 WA1200-6
Work equipment
4] Install screw (31).

a Install the screw after degreasing and
drying the threads completely.
a After tightening the screw, punch it at
a After tightening the screw, check that
unfastening torque is 41.2 to 88.2 Nm
{4.2 to 9 kgm}.
2 Threaded part:
Adhesive (Loctite No.262)
3 Screw:
58.9 to 73.6 Nm {6.0 to 7.5 kgm}
4) When using new parts for either or both of

piston rod (32) and piston assembly (30),
take the following steps for installation.
1] Using tool U5, tighten piston assembly
(30).
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
2] Make a hole to install the screw.
a Apply the drill tip to the groove where
the piston and piston rod are en-
gaged, and make a horizontal hole.
q Dimensions of a screw hole (mm):
Tap drill diameter: 10.3 q Bucket cylinder and lift arm cylinder
Tap hole depth: 43 1) Install head cover (2) onto cylinder rod (4).
Tap to be used: 12 x 1.75 2) Install two backup rings (8) and O-ring (9) to
Tap depth: 36 piston rod (4).
3] Remove steel chips and dust and clean a Do not try to force the backup ring into po-
the assembly completely. sition. Warm it in warm water at approx.
50 to 60 °C before fitting it.
3) Install piston (7) to piston rod (4).
4) Install spacer (6) and tighten mounting bolt
(5).
a Thoroughly clean threaded portion of the
piston bolt, and apply hardening acceler-
ator to six positions after degreasing.
2 Hardening accelerator:
Equivalent to LOCTITE Primer T
a After applying hardening accelerator, ap-
ply 0.5 to 0.7 cc of adhesive to six places
of the piston thread, and tighten the
mounting bolt.
2 Adhesive:
Equivalent to LOCTITE 262
3 Mounting bolt
Bucket cylinder:
245 to 309 Nm {25 to 31.5 kgm}
Lift arm cylinder:
490 to 608 Nm {50 to 62 kgm}
a After tightening, leave it for 30 minutes
(for adhesive setting).
WA1200-6 50-333
Work equipment
4) Remove cylinder assembly (1) from the tool.
4. Cylinder assembly
1) Set the cylinder to tool U2.
2) Install piston rod (4) to the cylinder.
3) Tighten mounting bolt (3) of head cover (2).

3 Mounting bolt
Steering cylinder:
1,150 ± 120 Nm {117.5 ± 12.5 kgm}
3 Bucket and lift arm cylinder:
2,450 ± 245 Nm {250 ± 25 kgm}
50-334 WA1200-6
Work equipment
Removal and installation of work equipment assembly
Removal and installation of work equipment assembly 50-3 5
Special tools 50-3 5

Standard
New/redesign
Necessity
equipment
Sketch
Sym-
Q'ty
Part No. Part name serial No.: Detail of work, remarks
bol
60001 and
up
SMT-890-5480 Forcing bolt q 2 Q STD Removal of work equipment pin (for
1
SMT-890-5491 Flanged nut q 2 Q STD f180 mm)
SMT-890-5460 Forcing bolt q 2 Q STD Removal of work equipment pin
2
SMT-890-5471 Flanged nut q 2 Q STD ((for f240 and 280 pins)
SMT-890-5310 q Plate q 1 Q STD
SMT-890-5320 q Guide bar q 2 Q STD Installation of work equipment pin
SMT-890-5330 q Flange nut q 1 Q STD
3 SMT-890-5340 q Push bolt q 1 Q STD
SMT-890-5350 q Leveling pad q 1 Q STD (P-16) (Commercially available)
For pin mounting bolt hole of 30 mm in
SMT-890-5360 q Adapter (30 mm) q 2 Q STD
diameter (*1)
For pin mounting bolt hole of 24 mm in
SMT-890-5370 q Adapter (24 mm) q 2 Q STD
diameter (*2)
SMT-890-5050 Plate q 1 Q Removal of collar (for f180 and 240
T 4 SMT-890-5070 Bolt q 4 Q pins)
5 Removal of collar (for f280 pin)
SMT-890-5070 Bolt q 4 Q
10 42C-98-11320 Plate q 1 Q STD Collar stopper plate for f180 pin
13 01017-51245 Bolt q 2 STD Collar tap bolt for pins of any size
Collar stopper plate mounting bolt (joint
01011-81265 Bolt q 2 STD
between lift arm and bucket)
01011-81250 Bolt q 2 STD
between bucket link and bucket)
14
01011-81230 Bolt q 2 STD
between lift arm and bell crank)
01010-81230 Bolt q 2
other than the above three joints)
15 42C-98-11350 Plate q 1 Q STD Fixing plate for press fit of bushing
*1 (For pin mounting bolt hole of 30 mm in diameter) *2 (For pin mounting bolt hole of 24 mm in diameter)
Lift arm tip and bucket, bell rank center, lift cylin- Bucket link and bucket, bucket link and bell
der rod, lift cylinder bottom, lift arm and front crank, bucket cylinder rod, bucket cylinder bot-
frame tom
WA1200-6 50-335
Work equipment
Sketch of tool (for 42C-98-*****) 50-3 6 T15: 42C-98-11350

a For SMT-890-*****, see the "Sketch of special (Fixing plate for press fit of bushing)
tool".
T10: 42C-98-11320
((Collar stopper plate for f180 mm pin)
T11: 42C-98-11330
T12: 42C-98-11340
50-336 WA1200-6
Work equipment
How to use special tools 50-3 7

1. How to use work equipment pin removal tool (T1 3) Screw in the forcing bolt of tool T1 or T2
or T2) (T1-1 or T2-1) into the flanged nut (T1-2 or
a Use removing tools T1 or T2 to remove the T2-2) installed in Step 2) to remove pin (10).
work equipment mounting pin.
q Tool T1: For pin of f180 mm
q Tool T2: For pins of f240 and 280 mm
2. How to use collar removal tool (T4 or T5)

a If the collar is hard to remove, use collar re-
moval tool T4 or T5 to remove it.
a Select plate T4 or T5 depending on the pin di-
ameter.
q Tool T4: For pin of f180 mm (A)
2) Through clearance (a) made in Step 1), : For pin of f240 mm (B)
install the flanged nut of tool T1 or T2 (T1-2 q Tool T5: For pin of f280 mm (C)
or T2-2 ) to the flange hole of pin (10).
1) Tool T4: For pins of f180 and 240 mm

q Install the plate of T4. Since the plate can
be used for both pins of f180 and 240
mm, use the bolt hole appropriate for the
pin.
WA1200-6 50-337
Work equipment
3. How to use the work equipment pin insertion tool

(T3)
a Use tool T3 to insert the work equipment pin.
1] Assemble tool T3.
a For details, see T3 (SMT-890-5300) in
"Sketches of special tools".
a Select the adapter of tool T3
depending on the bolt hole diameter.
24-mm bolt hole: SMT-890-5370
30-mm bolt hole: SMT-890-5360
2) Tool T5: For pin of f280 mm
2] Insert guide bar (T3-2) into the flange bolt

hole of pin (10), then install adapter
(T3-6) to the pin flange mounting bolt
hole.
a Use adapter (T3-6) depending on the
3) How to use (an example of use for f280 pin) diameter of the pin flange mounting
(1) Install four bolts (M12, L = 50 mm) in bolt bolt hole.
holes (a) to secure the plate (T5-1) of tool 24-mm bolt hole: SMT-890-5370
T5 to collar A (11) or collar B (12). 30-mm bolt hole: SMT-890-5360
a Use the collar forcing tap hole and use 3] Screw in bolt (T3-4) to insert pin (10).
the washer, too. a Do not use an impact wrench but use
(2) Tighten forcing bolt (T5-2) of tool T5 to a socket wrench to tighten the bolt.
remove collar A (11) or collar B (12). a To prevent the bushing seal assembly
installed to the collar from coming off,
never hit the pin with a hammer to in-
sert it.
50-338 WA1200-6
Work equipment
4. How to install the attached tools (collar stopper

plates (T10, T11, T12, T13 and T14) B type:
a The collar stopper pates T10, T11 and T12, When female threads for fixing the collar stopper
and the bolts T13 and T14 are provided for plate are cut directly in collar boss (12A).
each machine as standard attached tools. q Joint between bell crank and piston rod bucket
a Use tool T10, T11 or T12 depending on the cylinder (180-mm pin)
diameter of the mounting pin. 11. Collar A
Tool T10: For pin of f180 mm 11A. Collar boss on pin flange side
Tool T11: For pin of f240 mm 12. Collar B
Tool T12: For pin of f280 mm 12A. Collar boss on pin tip side
install the pin.
A type:
When female threads for fixing the collar stopper
plate are cut in the seat
q Joint between lift arm and bell crank (240-mm
pin)
q Joint between lift arm cylinder bottom and front
frame (240-mm pin) (*)
q Joint between lift arm and front frame (280-mm
pin)
q Joint between lift arm and piston rod of lift arm
cylinder (240-mm pin)
q Joint between bucket cylinder bottom and front
frame (180-mm pin) (*)
*: Removal of this part is not necessary when re-
moving or installing the work equipment assem-
bly
11. Collar A
12. Collar B
WA1200-6 50-339
Work equipment
C type:
When female threads for fixing the collar stopper
plate are cut in the dust intrusion prevention ring
a In this case, install snap ring (22) or (27),
then install dirt intrusion prevention ring (21)
or (26).
a For C type, use the ring horizontalizing bolt (24)
or (28) as the fixing bolt of tool T10, T11 or T12.
(180-mm pin)
q Joint between lift arm and bucket (240-mm
pin)
(180-mm pin)
11. Collar A
12. Collar B
22. Snap ring (*1)
27. Snap ring (*2)
(*2): Joint between bucket link and bucket,
and joint between bucket link and bell
crank
50-340 WA1200-6
Work equipment
Structure and name of work equipment connecting parts 50-341

1. Work equipment names and connecting parts
1. Lift arm A. Joint between bucket and lift arm

2. Bell crank B. Joint between bucket and bucket link
3. Bucket link C. Joint between bell crank and bucket link
4. Bucket D. Joint between piston rod of bucket cylinder and
5. Lift arm cylinder bell crank
6. Bucket cylinder E. Joint between bucket cylinder bottom and front
7. Front frame frame (*)
F. Joint between bell crank and lift arm
G. Joint between piston rod of lift arm cylinder and
lift arm
H. Joint between lift arm cylinder bottom and front
frame (*)
J. Joint between lift arm and front frame
*: Removal of this part is not necessary when re-
moving or installing the work equipment assem-
bly
WA1200-6 50-341
Work equipment
2. Structure and name of general connecting

parts
8. Bolt (pin flange fixing bolt) 16. Collar O-ring

9. Spacer 17. Bolt (cover fixing bolt)
10. Mounting pin 18. Washer
11. Collar A 19. Cover
11A. Collar boss A (*1) 20. O-ring (for cover)
12. Collar B 30. Shim for pin flange
12A. Collar boss B (*1) 31. Shim for collar end face
13. Bushing 32. Shim for pin end face
13A. Bushing boss (*2) 33. Plug (for gear oil refilling)
14. Bushing seal assembly 34. Plug (for gear oil draining)
15. Dust seal
<Reference>
*1: The portion to which the collar is installed is referred to as "collar boss".
*2: The portion to which the bushing is press fitted is referred to as "bushing boss".
50-342 WA1200-6
Work equipment
3. Connecting part equipped with the dirt prevention ring

(Joint between lift arm and bucket)
21. Ring (dirt intrusion prevention ring) 24. Bolt (ring horizontalization bolt)
22. Snap ring 25. Washer
23. Bolt (top and bottom ring fixing bolt)
(Joint between bucket link and bucket, and joint between bucket link and bell crank)
26. Ring (dirt intrusion prevention ring) 28. Bolt (ring horizontalization bolt)
27. Snap ring 29. Washer
WA1200-6 50-343
Work equipment
4. Features of work equipment connecting part q Clearance without tension: 5.1 mm

1. Lubrication of work equipment joints q Appropriate clearance after shim adjustment:
Lubricated type work equipment pins and bush- 0.5 to 0.7 mm
ings are employed for lubricating the work equip-
ment joints.
2. In order to prevent leakage of oil, the bushing
seal assembly and O-ring are installed to the
contact portions between the parts to provide the
sealing function.
3. Bushing seal assembly (14) is provided with
tension enough to secure the sealing perfor-
mance.
4. To give bushing seal assembly (14) required
tension, shims are installed to each part of work
equipment pin, collar A (11) and collar B (12).
5. Work equipment joint parts must be installed so
that an appropriate clearance is secured
between bushing (13) and collar A (11), and
between bushing (13) and collar B (12) to
provide bushing seal assembly (14) with enough
tension.
50-344 WA1200-6
Work equipment
Removal 50-345
k Before performing removal, be sure to imple- 3) Remove mounting bolts (17) and washers
ment "2. Preparatory work" and "3. Precau- (18) of cover (19) installed to mounting pin
tions during work" in "00 Safety notice". (10) connecting link (3) and bucket (4), and
k Since oil is contained in the mounting pin, remove the cover.
prepare a container to receive the oil and a When the cover is hard to remove, use
drain the oil from the oil drain plug on the the forcing tap to remove it.
flange side of the mounting pin. a Forcing tap: M12 x 1.75 (2 places)
1. Removal of pin connecting bucket and bucket the mounting pin flows out when the cov-
link er is removed.
1) Sling bucket link (3).
4 Bucket link:
650 kg

four spacers (9) of mounting pin (10), then
pull out mounting pin (10) using special tool
2) Remove fixing bolt (28) and washer (29) of T1.
ring (26) of the joint between bucket link (3) 4 Mounting pin:
and bucket (4). 80 kg
tools".
5) Disconnect bucket link (3) from bucket (4),
then remove ring (26) and snap ring (27).
4 Bucket link:
650 kg
WA1200-6 50-345
Work equipment


connecting the bucket and bucket link.
2. Removal of pin connecting bell crank and bucket

link
1) Sling bucket link (3).
4 Bucket link:
650 kg

bucket (4).
a Length of collar
q Collar A (11) and collar B (12): 109.3
mm
special tools".
50-346 WA1200-6
Work equipment
2) Remove fixing bolts (28) and washers (29) of 5) Disconnect bucket link (3) from bell crank (2),
ring (26) of the joint between bucket link (3) then remove ring (26) and snap ring (27).
and bell crank (2). 4 Bucket link:
650 kg

(10) connecting link (3) and bell crank (2),
and remove the cover.
the forcing tap to remove it.
a Forcing tap: M12 x 1.75 (2 places)
er is removed.

T1.
4 Mounting pin:
80 kg
tools".
WA1200-6 50-347
Work equipment
6) Remove collar A (11) and collar B (12) from 3. Removal of pin connecting lift arm and bucket
bell crank (2). 1) Sling lift arm (1).
q Length of collar A (11) and collar B (12): 4 Lift arm (single unit):
91.3 mm 17,850 kg
a If collars A and B are hard to remove, use Purpose: To prevent the lift arm from
special tool T4 to remove them. lowering due to its own weight when
a For the collars A and B removal proce- mounting pin (10) is removed.
special tools".
2) Remove ring fixing bolts (24) and washers

(25) of ring (21) of the joint between bucket
(4) and lift arm (1).

connecting the bell crank and bucket link.
50-348 WA1200-6
Work equipment
3) Remove mounting bolts (17) and washers 5) Taking the same procedures in Steps 1) to
(18) of cover (19) installed to mounting pin 4), remove the other mounting pin
(10) connecting bucket (4) and lift arm (1), connecting the bucket and lift arm.
and remove the cover. 6) Sling bucket (4) and disconnect it from lift
a When the cover is hard to remove, use arm (1).
the forcing tap to remove it. 4 Standard bucket (20 m ):
3
a Forcing tap: M12 x 1.75 (2 places) 21,050 kg
er is removed.
7) Remove ring verticalization bolt (23), ring

(21) and snap ring (22).

T2.
4 Mounting pin:
170 kg
tools".
WA1200-6 50-349
Work equipment
8) Remove collar A (11) and collar B (12) from 4. Removal of pin connecting bell crank and piston
bucket (4). rod of cylinder
4 Collars A and B (single unit): 1) Insert a block between bell crank (2) and lift
22 kg arm (1) to fix bell crank (2).
q Length of collar A (11) and collar B (12): k Be sure to fix the bell crank since it
121.8 mm comes down when the mounting pin
a If collars A and B are hard to remove, use on the bucket cylinder piston rod side
special tool T4 to remove them. is removed.
a For the collars A and B removal proce- 2) Sling bucket cylinder assembly (6).
dure using special tool T4, see "2. How to 4 Bucket cylinder assembly:
use collar removal tool" in the "How to use 1,400 kg
special tools".

9) Remove bushing seal assembly (14), dust washers (18) of cover (19) installed to
seal (15) and collar O-ring (16) from collar A mounting pin (10) connecting bell crank (2)
(11) and collar B (12). and piston rod of bucket cylinder (6), and
remove the cover.
er is removed.
50-350 WA1200-6
Work equipment
4) Remove four pin flange fixing bolts (8) and 6) Remove collar A (11) and collar B (12) from
four spacers (9) of mounting pin (10), then bell crank (2).
pull out mounting pin (10) using special tool q Length of collar A (11) and collar B (12):
T1, and disconnect bell crank (2) from the 91.3 mm
piston rod of bucket cylinder (6). a If collars A and B are hard to remove, use
4 Mounting pin: special tool T4 to remove them.
70 kg a For the collars A and B removal proce-
k Check that the bell crank is fixed since dure using special tool T4, see "2. How to
it comes down when the mounting pin use collar removal tool" in the "How to use
is removed. special tools".
tools".

5) After removing mounting pin (10), prop up

and fix bucket cylinder (6) so that it is out of
the way.
8) Taking the same procedure in Steps 1) to 7),

disconnect the other pin connecting the bell
crank and piston rod of the bucket cylinder.
WA1200-6 50-351
Work equipment
5. Removal of pin connecting bell crank and lift arm 3) Remove pin flange fixing bolts (8) and
1) Sling bell crank (2). spacers (9) of mounting pin (10), then pull out
4 Bell crank: mounting pin (10) using special tool T2, and
2,450 kg disconnect bell crank (2) from lift arm (1).
4 Mounting pin:
170 kg
tools".
2) Remove four mounting bolts (17) and four

mounting pin (10) connecting bell crank (2)
and lift arm (1), and remove the cover.
a Forcing tap: M12 x 1.75 (2 places) 4) Sling and remove bell crank (2).
a Prepare an oil container since the oil in 4 Bell crank:
the mounting pin flows out when the cov- 2,450 kg
er is removed. 5) Remove collar A (11) and collar B (12) from
lift arm (1).
4 Collars A and B (single unit):
22 kg
121.8 mm
special tools".
50-352 WA1200-6
Work equipment
6) Remove bushing seal assembly (14), dust 3) Remove mounting bolts (17) and washers
seal (15) and collar O-ring (16) from collar A (18) of cover (19) installed to mounting pin
(11) and collar B (12). (10) connecting lift arm (1) and the piston rod
of lift cylinder (5), and remove the cover.
er is removed.

disconnect the other pin connecting the bell
crank and lift arm.

1) Fix lift arm (1).
2) Sling lift cylinder assembly (5).

2,950 kg
WA1200-6 50-353
Work equipment
4) Remove pin flange fixing bolts (8) and four 6) Remove collar A (11) and collar B (12) from
spacers (9) of mounting pin (10), then pull out lift arm (1).
mounting pin (10) using special tool T2. q Length of collar A (11) and collar B (12):
4 Mounting pin: 101.8 mm
140 kg a If collars A and B are hard to remove, use
a For the mounting pin removal procedure, special tool T4 to remove them.
see "1. How to use work equipment pin a For the collars A and B removal proce-
removal tool" in the "How to use special dure using special tool T4, see "2. How to
tools". use collar removal tool" in the "How to use
special tools".
5) After removing mounting pin (10), place

blocks [1] between lift arm cylinder (5) and 7) Remove bushing seal assembly (14), dust
front axle (35) to fix lift arm cylinder (5). seal (15) and collar O-ring (16) from collar A
a Dust seal (15) is installed to the machine
with serial number 50077 and up.

remove the other pin connecting the lift arm
and piston rod of the lift arm cylinder.
50-354 WA1200-6
Work equipment
7. Removal of lift arm angle sensor 3) Remove mounting bolts (17) and washers
1) Remove cover (36). (18) of cover (19) installed to mounting pin
2) Remove lever(37). (10) connecting lift arm (1) and front frame
3) Disconnect wiring harness connector F04 (7), and remove the cover.
(38) and remove clamp (39). a When the cover is hard to remove, use
4) Remove lift arm angle sensor (41). the forcing tap to remove it.
er is removed.
8. Removal of pin connecting lift arm and front

fame
1) Check that lift arm (1) is fixed.

T2.
4 Mounting pin:
230 kg
tools".
2) Sling lift arm (1).

4 Lift arm (single unit):
17,850 kg
WA1200-6 50-355
Work equipment
5) Remove collar A (11) and collar B (12) from 7) Taking the same procedure in Steps 3) to 6),
front frame (7). remove the other pin connecting the lift arm
4 Collars A and B (single unit): and front frame.
40 kg 8) Remove lift arm (1)
q Length of collar A (11) and collar B (12): 4 Lift arm:
174.7 mm 17,850 kg
special tools".
9. Removal of the bushing press fitted to the work

equipment and cylinders
1) When replacing bushing (13) press fitted to
the work equipment and cylinder, gas cut
a Take care not to melt bushing boss (13A) in
6) Remove bushing seal assembly (14), dust gas cutting.
50-356 WA1200-6
Work equipment
Outline of shim selection for installing mounting

pin (Outline of shim adjustment procedure) 50-357
1. Outline of shim adjustment
q At the final stage of assembling the work
equipment, provide a clearance of 0.5 to 0.7
mm between bushing (13) and collar A (11),
and between bushing (13) and collar B (12).
3. Names, thickness, and shapes of shims

q Pin flange shim: Installed to the pin flange
Available shims: 0.5 mm (one type)

mm.
2. Work equipment joints to which shims are

installed
q (10): Mounting pin
q (11): Collar A
q (12): Collar B
q (13): Bushing
q (19): Cover
q (30): Shim for pin flange
q (31): Shim for collar end face
q (32): Shim for pin end face
WA1200-6 50-357
Work equipment
q Collar end face shim: Installed to the collar q Pin end face shim: Installed to the pin end
end face face
Available shims: 0.3 mm and 0.5 mm (two Available shims: 0.3 mm and 0.5 mm (two
types) types)
50-358 WA1200-6
Work equipment
4. List of part numbers of shims used for each part

Shim thick- Part number of
Pin diameter Part number of pin
Shim installed position ness collar end face Part number of pin
(mm) flange shim
(mm) shim end face shim
0.5 42C-70-12920 42C-70-11880 42C-70-11840
Joint between lift arm and bucket f240
0.3 – 42C-70-11780 42C-70-11830
Joint between bucket and bucket 0.5 42C-70-12910 42C-70-11870 42C-70-11860
f180
link 0.3 – 42C-70-11770 42C-70-11850
Joint between bell crank and 0.5 42C-70-12910 42C-70-11870 42C-70-11860
f180
bucket link 0.3 – 42C-70-11770 42C-70-11850
Joint between bell crank and pis- 0.5 42C-70-12910 42C-70-11870 42C-70-11860
f180
ton rod of bucket cylinder 0.3 – 42C-70-11770 42C-70-11850
Joint between bucket cylinder 0.5 42C-70-12910 42C-70-11870 42C-70-11860
f180
bottom and front frame 0.3 – 42C-70-11770 42C-70-11850
Joint between lift arm and bell 0.5 42C-70-11920 42C-70-11880 42C-70-11840
f240
crank 0.3 – 42C-70-11780 42C-70-11830
Joint between lift arm and piston 0.5 42C-70-12920 42C-70-11880 42C-70-11840
f240
rod of lift arm cylinder 0.3 – 42C-70-11780 42C-70-11830
Joint between lift arm cylinder 0.5 42C-70-12930 42C-70-11880 42C-70-11840
f240
bottom and front frame 0.3 – 42C-70-11780 42C-70-11830
Joint between lift arm and front 0.5 42C-70-12940 42C-70-11890 42C-70-11820
f280
frame 0.3 – 42C-70-11790 42C-70-11810
5. Selection procedure of shims used (types and 2) Insert collar A (11) and B (12) to collar boss
thicknesses of shims) A (11A) and B (12A).
1) Install tool T15 (fixing plate used when press Reference: The portion to which the collar is
fitting the bushing) to bushing boss (13A) and installed is referred to as "collar boss".
press fit bushing (13) to bushing boss (13A). a Do not install the bushing seal assembly,
Reference: The portion to which the bushing collar O-ring and dust seal to collar A (.11)
is press fitted is referred to as "bushing and collar B (12).
boss". 3) Install bushing boss (13A) and do center
a For the press fitting procedure of the alignment of bushing (13) with collar A (11)
bushing, see Installation, "2 Installation and B (12).
(press-fit) of bushing to bushing boss". a When installing bushing boss (13A), keep
collar A (11) and B (12) 10 mm out of the
collar boss.
WA1200-6 50-359
Work equipment
4) Fix collar A (11) (collar on the pin flange side) 6) Push the end face of collar A (11) inward to
using pin flange fixing bolts (8) and spacers make its face contact bushing (13), then
(9). measure "dimension a", that is the travel of
collar A (11) with respect to the end face of
collar boss A (11A), and note it in Attached
Table 1.
a When collar A (11) is out of the end face
of collar boss A (11A), bushing (13) is
pressed against collar A (11) by the pin
flange fixing bolt. But when collar A (11) is
inside the end face of collar boss A (11A),
you must push in collar A (11) with your
hand to make it contact closely with bush-
ing (13).
a In order to avoid confusion in the mea-
sured results, attach the travel signs of +
(plus) or - (minus) as shown below to the
5) Collar B (12) must be against bushing (13). measured "dimension a" as well as "di-
Install fixing tool T10, T11, or T12 (collar mension b" and "dimension c" that are to
stopper plate) to collar B (12) using T14 be measured in the succeeding steps.
(plate mounting bolt). Then screw in T13 Above symbols + and - represent the di-
(collar tap bolt) to push collar B (12) toward mensional difference with the collar end
bushing (13) until the tightening torque face and collar boss end face.
becomes large (bushing (13) is in close a For dimension a
contact with collar B (12)). When collar A (11) is outside end face
a For how to install tools T10, T11, T12, of collar boss A (11A):
T13 and T14, see "4 How to use attached -a1 (- indication)
tools (collar stopper plate)" in the "How to When collar A (11) is inside end face
use special tools". of collar boss A (11A):
+a2 (+ indication)
a For dimension b
When collar B (12) is outside end face
of collar boss B (12A):
-b1 (- indication)
When collar B (12) is inside end face
of collar boss B (12A):
+b2 (+ indication)
a For dimension c
When end face of mounting pin is
outside collar B (12):
-c1 (- indication)
When end face of mounting pin is
inside collar B (12):
Inside: +c2 (+ indication)
When collar A (11) is outside the end face of
collar boss A (11A) (-a1 indication)
50-360 WA1200-6
Work equipment
8) Measure the travel of the end face on pin tip

side of collar B (12) with respect to collar
boss B (12A), that is "dimension b", and note
it in Attached Table 1.
When collar B (12) is outside the end face of
collar boss B (12A) (-b1 indication)
When collar A (11) is inside the end face of

collar boss A (11A) (+a2 indication)
When collar B (12) is inside the end face of

collar boss B (12A) (+b2 indication)
7) When collar A (11) is 0.5 to 0.7 mm or more

inside the end face of collar boss A (11A),
calculate the necessary shim pack thickness
and prepare shim (31) for the collar end face.
Apply oil to the shim beforehand and install it
to mounting pin (10).
a Necessary shim pack thickness: Dimen-
sion a -0.5 (an appropriate clearance be-
tween collar A and bushing)
a When you have installed the collar end
face shim to the mounting pin, calculate
"dimension a" after the insertion and note
it in Attached Table 1. (Correction of di-
mension a)
WA1200-6 50-361
Work equipment
9) Remove pin flange fixing bolts (8) and

spacers (9), then loosen tool T13 (collar tap 13)Measure "dimension a" and "dimension b"
bolt) sufficiently to move collar A (11) and again in the same positions as that used in
collar B (12) 10 mm apart from the collar steps 6) and 8) and note the measurements
boss. Then remove the bushing boss from in Attached Table 1.
the collar bosses once. a "Dimension a" and "dimension b" ob-
10)Install bushing seal assembly (14), collar tained in this measurement should be al-
O-ring (16) and dust seal (15) to collar A (.11) most the same as "dimension a" and
and collar B (12). "dimension b" obtained in steps 6) and 8)
11)Install bushing boss (13A) and do center respectively. If a large difference (4 to 5
alignment of bushing (13) with collars A (11) mm or greater) is found between them,
and B (12), then insert mounting pin (10) to bushing seal assembly (14) fitted to the
collar A (11). side face of collars A (11) and B (12)are
a When installing bushing boss (13A), keep probably out of position. The above mea-
collar A (11) and B (12) 10 mm out of the surement is to finally check that bushing
collar bosses. seal assembly (14) is fitted in position re-
spectively.
a "Dimension a" and "dimension b" ob-
tained in this Step 13) may not be identi-
cal to "dimension a" and "dimension b)
obtained in Steps 6 and 8), and "correct-
ed dimension a" calculated in Step 7)
(there are sometime a difference of 1 to 2
mm). Such difference results because the
position of bushing boss (13A) in Steps 6)
and 8) and the position of bushing boss
(13A) in this step (13) are not necessarily
the same. In such case, use "dimension
a" and "dimension b" obtained in this step
13) as the final dimensions.
When collar A (11) is outside the end face of
12)Fix mounting pin (10) using pin flange fixing
collar boss A (11A) (-a1 indication)
bolt (8) and spacer (9) temporarily but
securely.
Fix tool T10, T11, or T12 (collar stopper
plate) to collar B (12) using tool T14 (plate
mounting bolt) and screw in tool T13 (collar
tap bolt) to fix collar B (12) firmly. (Bushing
(13) with bushing seal assemblies (14) on
both sides is in close contact with collars A
(11) and B (12).)
a For how to install tools T10, T11, T12,
T13 and T14, see "4 How to use attached
tools (collar stopper plate)" in the "How to
use special tools".
50-362 WA1200-6
Work equipment
When collar A (11) is inside the end face of 14)Measure the travel of collar B (12) with
collar boss A (11A) (+a2 indication) respect to the end face of mounting pin (10),
"dimension c", and note it in Attached Table
1.
a Location of measurement for "dimension
c" must be the same as that used for mea-
suring "dimension b".
a When measuring "dimension c", the
mounting pin tip may be outside or inside
the end face of collar B (12).
When end face of mounting pin (10) is
outside collar B (12) (-c1 indication):
When collar B (12) is outside the end face of

collar boss B (12A) (-b1 indication)
When end face of mounting pin (10) is inside

collar B (12) (+c2 indication):
When collar B (12) is inside the end face of

collar boss B (12A) (+b2 indication)
WA1200-6 50-363
Work equipment
15)Determine the type and numbers of the 18)Prepare shim packs finally used and install
shims for collar A (11) from "dimension a" or them to the necessary portions (collar A side
"corrected dimension a" in Attached Table 1 and collar B side) to perform the final assem-
to provide an appropriate clearance (0.5 to bling.
0.7 mm) between bushing (13) and collar A <Reference 1>
(11). q If, for instance, the final travel of collar A
a Note that the shim pack for the end face (11) with respect to collar boss A (11A),
of collar A (11) is already installed in step that is "dimension a" or "correction of di-
7). mension a", is +0.15 mm (collar A (11) is
16)Determine the type and numbers of the inside collar boss A (11A)), adjusting the
shims for collar B (12) from "dimension c" in clearance between collar A (11) and
Attached Tables 1 and 2 to provide an appro- bushing (13) to 0.5 mm theoretically re-
priate clearance (0.5 to 0.7 mm) between quires to move collar A (11) (= pin flange
bushing (13) and collar B (12). position) 0.35 mm (0.15 mm - 0.5 mm)
a In this case, note that the installed posi- outside. To that end, the mounting pin in-
tion of mounting pin (10) is finally dis- stalled position (= pin flange position)
placed by the thickness of shim pack for must be moved 0.35 mm outside (installa-
the pin flange of collar A (11). tion of shims for the pin flange).
17)Remove pin flange mounting bolts (8), q The minimum pin flange shim thickness
spacers (10) and tools (such as collar beyond 0.35 mm is a single 0.5 mm thick
stopper plate and collar tap bolt) T10, T11, shim.
T12, T13 and T14 on collar A (11) side. a Theoretically, the clearance between col-
lar A (11) and bushing (13) becomes 0.65
mm (0.15 mm + 0.5 mm).
q Therefore, all you need to do is to insert a
single 0.5 mm shim for the pin flange. (In
this case, the mounting pin is finally slid
0.5 mm toward collar A (11) side and fixed
there from the position where the travel
was measured.)
(See Attached Tables 3 and 4.)
<Reference 2>
q For example, if the final travel, "dimension
c", of the pin tip with respect to collar B
(12) is +1.3 mm (the mounting pin tip is in-
side collar B (12)), the mounting pin tip is
finally slid +0.5 mm by the pin flange shim
on collar A (11) toward collar A (11) side.
Therefore, the clearance between collar
B (12) and mounting pin tip becomes +1.8
mm (1.3 mm + 0.5 mm).
q Then collar B (12) must be moved further
to outside to provide 0.5 mm clearance
between collar B (12) and bushing (13).
q The final theoretical travel of the mount-
ing pin tip with respective to collar B (12)
is 2.3 mm (1.8 mm + 0.5 mm). The mini-
mum thickness of the pin tip face shim be-
yond 2.3 mm is provided by four 0.5 mm
shims and a 0.3 mm shim.
a Theoretically, the clearance between col-
lar B (12) and bushing (13) becomes 0.5
mm.
q Therefore, four 0.5 mm shims and a 0.3
mm shim for the pin tip face serves the
purpose.
(See Attached Tables 4-1 to 4-4.)
50-364 WA1200-6
Work equipment
Installation 50-365
1. General work equipment installation procedure
(connection of work equipment)
1) Press fit of bushings to necessary locations
2) Installation of bell crank to lift arm (right and
left sides)
3) Installation of bucket link to bell crank (right
and left sides)
4) Installation of lift arm to front frame
5) Installation of piston rod of lift arm cylinder to
lift arm (right and left sides)
6) Installation of piston rod of bucket cylinde to
bell crank (right and left sides)
7) Installation of bucket to lift arm (right and left
sides)
2) Cool bushing (13) using liquid nitrogen for 60
8) Installation of bucket link to bucket (right and
minutes or more.
left sides)
3) After cooling bushing (13) with liquid
a Check the parts assembled for scratches and
nitrogen, insert it to bushing boss (13A).
dents, then remove soil, dirt and stains on the
a Be sure not stop insertion work halfway. If
coating.
you stop the operation halfway, the bush-
a Eliminate rusts, if any.
ing becomes immovable and you have to
a When you have replaced mounting pin (10),
remove it.
chamfer "a" portion in the shaft tip to make it
a After inserting the bushing, check both
smooth.
sides of the bushing boss for protrusion of
the bushing. If protrusion is recognized,
remove the bushing and insert it again.
2. Installation (press fit) of bushing to bushing boss

a Prepare liquid nitrogen before starting as-
sembling.
a The following describes the installation
1) Install special tool T15 (fixing plate used
procedures of the typical connecting
when press fitting the bushing) to bushing
parts.
boss (13A).
boss".
a Install special tool T15 using the screw
hole of the bushing boss on the opposite
side of the bushing boss to which the
bushing is inserted.
a Use care when installing the bushing to
the location where special tool T15 can-
not be installed (locations for bushings
such as the bushing for lift arm cylinder
and bushing for bucket cylinder).
WA1200-6 50-365
Work equipment
3. Temporary insertion of collars A and B to the

collar boss 2) Insert collar A (11) and collar B (12) to collar
Purpose: To measure travel of collars A (11) and boss A (11A) and B (12A).
B (12) with respect to end face of collar 3) Put the inner end face of collar A (11) and B
bosses A (11A) and B (12A) for adjust- (12) approximately 10 mm out of the inner
ment with shims. face of collar boss A (11A) and B (12A).
a Do not install the bushing seal assembly, Purpose: To prevent interference between
dust seal and collar O-ring to collar A (.11) the collar and bushing boss when
and collar B (12). inserting the bushing boss between
a If collar A (11) or B (12), and collar boss A the collar bosses.
(11A) or B (12A) is rusted, remove the rusts
using sandpaper and such. Remove at-
tached foreign substances, if any.
1) Apply lubricant to the inside of collar boss A
(11A) and B (12A) and the periphery of collar
A (11) and B (12).
Purpose: To make insertion of the collar to
the collar boss easier and prevent rusting of
the collar and collar boss.
2 Inside of collar boss:
(LM-P)
2 Periphery of collar:
(LM-P)
4. Center alignment of collars A and B and bushing
a Apply as much lubricant as possible to
a As for a position where the dirt intrusion pre-
the inside of the collar boss.
vention ring is installed, install the dirt intru-
a Apply lubricant with your hands without
sion prevention ring to the bushing boss first,
using a brush. Do not use a brush since
then install the bushing boss between the
its bristles can adhere to the collar or col-
collar bosses. For details, see "14 Installation
lar boss.
of dirt intrusion prevention ring".
1) Sling bushing boss (13A) using a crane and
install it between collar boss A (11A) and B
(12A).
50-366 WA1200-6
Work equipment
2) Align the center of collars A (11) and B (12) 5. Fixing of collars A and B from both sides of collar
and bushing (13). boss
a Check that collars A (11) and B (12) do 1) Push in collar A (11) toward bushing (13),
not contact bushing boss (13) but are in then fix collar A (11) using pin flange fixing
close contact with bushing (13) when they bolts (8) and spacers (9) to make collar A
are pushed toward bushing (13). (11) and bushing (13) in close contact with
each other.
a When fixing, apply moderate force using
a combination wrench or spanner without
resorting to an impact wrench or torque
wrench.
a If collar A (11) is inside the outer end face

of collar boss A (11A) and clearance (a) is
left, you must push collar A (11) with your
hand in the clearance measurement to
make it contact bushing (13).
2) Install the collar stopper plate of tool T10,

T11, or T12 to collar B (12) using a tool T14
bolt (including a washer) or the bolt for hori-
zontal fixing of the dirt intrusion prevention
ring and washer.
WA1200-6 50-367
Work equipment
a There are three approaches A, B and C in 4) Check that clearance (a) is not left. The clear-
installing the collar stopper plate of tools ance can be left if collar A (11) is inside the
T10, T11 and T12. For details, see "4. At- outer end face of collar boss A (11A).
tached tools (collar stopper plate) installa- Purpose: If clearance (a) is left, a clearance
tion procedure" in "How to use special results between collar A (11) and
tools". bushing (13), requiring insertion of the
collar end face shim to collar A (11).
3) Make bushing (13) contact collar B (12) by

pushing in collar B (12) toward bushing (13), 6. Measurement and note of travel of collars A and
then fix it firmly by tightening it using tool T13 B
(collar tap bolt). a This dimension measurement is important to
the determination of the shim installation po-
sitions and shim pack thickness (types and
numbers of shims).
a If collars A and B are inside the outer end
face of collar bosses A and B, prefix + (plus)
to the dimension recorded.
a If collars A and B are outside the outer end
face of collar bosses A and B, prefix - (minus)
to the dimension recorded.
a Conduct measurement in the right and left
sides and upper and lower positions of a flat
place on the collar boss end face, and then
calculate their mean. When the entire periph-
ery of the collar boss end face is not ma-
chine-worked, find a flat, easy to measure
location and use it as the reference position
of the measurement.
a Use vernier caliper [2] as the measuring in-
strument and do the measurement in the fol-
lowing manner.
50-368 WA1200-6
Work equipment
1) Note of travel of collar A (11) with respect to 2) Note of travel of collar B (12) with respect to
collar boss A (11A) collar boss B (12A)
Note the measurement as "dimension a" in Note the dimension as "dimension b" in
No.1.1 of Attached Table 1. No.1.1 of Attached Table 1.
a In many cases, the standard dimension a When collar B (12) is outside the outer
(dimension a) of collar A is almost 0 mm. end face of collar boss B (12A):
: Note "value of almost 0" as "-a11 dimen- Note the value as "-b11 dimension".
sion"
a When collar A (11) is outside the outer
end face of collar boss A (11A):
Note the measurement as "-a11 dimen-
sion".
a When collar B (12) is inside the outer end

face of collar boss B (12A):
Note the value as "+b21 dimension".
a When collar A (11) is pushed toward in-

side (to the bushing), it can enter inside
the outer end face of collar boss A (11A)
though rarely.
: Note the value as "+a21 dimension".
WA1200-6 50-369
Work equipment
7. Preparation for insertion of pin 5) Clean the inner surface and side face of
1) Remove pin flange fixing bolts (8) and collar A (11) and B (12) using a piece of cloth
spacers (9) that are fixing collar A (11). and apply a large volume of gear oil.
2) Loosen tool T13 bolt that is fixing collar B 2 Collars A and B (inner surface and
(12), remove tool T14 fixing bolt and remove side face):
tool T10, T11, or T12 from the collar boss Gear oil (GL-5)
once. a It is allowed to do the same work with col-
lars A and B removed from respective col-
lar bosses A and B once.
6) Remove dusts from bushing seal assembly
(14), dust seal (15), and collar O-ring (16) to
be installed to collars A (.11) and B (12), then
apply gear oil to them.
3) Put collar A (11) and B (12) approximately 10

mm out of collar boss A (11A) and B (12A).
4) Remove bushing boss (13A) being slung with
a crane from between the collar bosses
once.
a When removing the bushing boss, put the
collars A and B 10 mm out of the end face a Handle floating seal (14-1) and square
of the collar bosses A and B to prevent in- ring (14-2) that consist of bushing seal as-
terference with the collars A and B. sembly (14) with care since they can be
easily detached.
a If floating seal (14-1) and square ring
(14-2) are detached, install them again to
the floating seal paying attention to the di-
rection of the square ring.
50-370 WA1200-6
Work equipment
7) Install bushing seal assembly (14), dust seal a Take care not to install collar O-ring (16)
(15) and collar O-ring (16) to collars A (.11) twisted.
and B (12). a Take care not to install dust seal (15) fac-
a In this step, be sure not to allow adhesion ing wrong direction when installing it to
of foreign substances such as sands. the collar.
Smaller inner diameter side of dust seal:
Outside (A)
Larger inner diameter side of dust seal:
Inside (B)
(Collar O-ring side)
a Other than the above, you can install

bushing seal assembly (14) to collars A
(11) and B (12) when istalling mounting
pin (10) to collar A (11). Both are accept-
able as the installation timing.
WA1200-6 50-371
Work equipment
a When installing bushing seal assembly 8) After installing bushing seal (14) to collars A
(14), install floating seal (14-1) and (11) and B (12), put collars A (11) and B (12)
square ring (14-2) with care so that they 10 mm out of collar bosses A (11A) and B
are fitted in position. (12A) to prevent bushing seal assembly (14)
And take care not to install bushing seal protruding out of the end face of collar
(14) facing wrong direction. bosses A (11A) and B (12A).
Floating seal (14-1): Outside (bushing Purpose: To prevent interference between
side) the bushing seal assembly and the
Square-ring (14-2): Inside bushing boss to be inserted later.
9) After removing foreign substances on the

inner face and side face of bushing (13) with
a cloth, apply a thin film of lubricant uniformly
to these locations and then apply gear oil.
2 Bushing (inner surface and side
face):
(LM-P) (A thin film of LM-P)
2 Bushing (inner surface and side
face):
Gear oil (GL-5)
(after a thin film of LM-P is applied)
50-372 WA1200-6
Work equipment
a If lubricant (LM-P) is excessive, lubricant 11)If end face of collar A (11) is found to be
(LM-P) can mix with gear oil in mounting inside the collar boss in step 6 "Measurement
pin (10) while the machine is operation. and note of travel of collars A and B", select
And the resulting sediments (D) of lubri- the thickness and numbers of collar end face
cant can clog gear oil lubricating hole (C) shims (31) and the numbers of pin flange
of mounting pin (10), blocking circulation shims in such that they coincide with the shim
of gear oil. Thus, you must not apply an thickness obtained by subtracting the clear-
excessive volume of lubricant. ance (0.5 to 0.7 mm) between collar A and
A: Oil level bushing from +a2 dimension. Then apply oil
B: Oil circulation path to the collar end face shims and install them
C: Oil circulation hole to the mounting pin (10) beforehand.
D: Sediments of lubricant that cloggs the
oil circulation hole
a After installing the collar end face shims

to the mounting pin, note the shim thick-
10)Check mounting pin (10) and inside hole of ness and number of shims used, and also
the pin for adhesion of sands and rusts. And calculate and note "dimension a" after in-
eliminate them, if any. sertion of the shims in No.1.2 of Attached
a Particular attention is required to the in- Table 1.
side of the hole at the center of the pin in q Note the thickness and numbers of
which sands and rusts tend to adhere. (If the installed collar end face shims,
rusts are gathered, remove them using a and also note the total shim pack
sandpaper.) thickness.
q "Dimension a" after collar end face
shims are inserted to pin: Note the val-
ue as "+a22 dimension".
a Install the collar end face shims to the pin,
As for the pin flange shims, just prepare
them without installing them to the pin.
<Example>
A shim is not necessary when +a2 = +0.5 to
0.7 mm
a Since an appropriate clearance is
maintained between collar A and
bushing in the range of 0.5 to 0.7 mm.
When +a2 = +0.8 mm, select a 0.3 mm collar
end face shim.
a Clearance between collar A and bush-
ing becomes 0.5 mm.
When +a2 = +0.3 mm, select a 0.3 mm collar
end face shim and 0.5 mm pin flange shim.
a Clearance between collar A and bush-
ing becomes 0.5 mm.
WA1200-6 50-373
Work equipment
12)Tie mounting pin (10) with belt [1] and sling it Type B: Installing mounting pin (10) equipped
using a crane. with collar A (11) at its tip to collar boss
k Pay attention to the balance after tying A (11A) after removing collar A (11)
with the belt. once from collar boss A (11A).
13)After slinging mounting pin (10) using the
crane, apply gear oil uniformly from the belt
to the tip of the mounting pin.
2 Mounting pin:
Gear oil (GL-5)
"Purpose" is to ensure smooth insertion of
the pin to collar A.
a Apply gear oil with your hands without us-
ing a brush (bristles may adhere to them).
a These are the two istallation methods. Select

a suitable one depending on the situation.
[Prohibited action: Ban on unascertainable work]
q Other than types A and B above, there is an-
other mounting pin (10) insertion approach.
In which, collar A (11) is inserted up to the
flange side of mounting pin (10) for the center
alignment with collar B (12) and bushing (13).
Then after mounting pin (10) is inserted to
8. Installation of pin to collar A bushing (13), collar A (11) is inserted to collar
The following lists different approaches boss A (11A). In this case, however, confir-
employed when installing the pin. mation of detachment of bushing seal as-
Type A: Installing mounting pin (10) to collar A sembly (14) becomes unavailable when
(11) while leaving collar A (11) inserting collar A (11) to collar boss A (11A).
installed to collar boss A (11A). Therefore, this approach must not be em-
ployed.
50-374 WA1200-6
Work equipment
3] When installing bushing seal assembly

(14) at this point, apply gear oil to bushing
seal assembly (14) and install it to collars
A (11) and B (12) making it face the
correct direction.
q Floating seal (14-1): Outside (bushing
side)
q Square-ring (14-2): Inside
a The following describes Type A mounting pin

installation method.
1] Install mounting pin (10) to collar A (11),
which has been installed to collar boss A
(11A).
a When the collar end face shim is se-
lected in step 7-11), install it to the
mounting pin beforehand.
2] When the tip of mounting pin (10) came a To prevent bushing seal assembly
near to the inner end face of collar A (11), (14) from jumping out of the inner end
stop the installation once. face of respective collar bosses A
a At this point, collar A (11) may be (11A) and B (12A), position collars A
pushed to move by mounting pin (10) (11) and B (12) 10 mm out of the inner
and, as a result, bushing seal (14) in- end face of the respective collar boss-
stalled to collar A (11) can jump out of es in advance.
the inner end face of collar boss A
(11A) on collar A (11) side. To prevent
such jumping, collar A (11) must be
positioned 10 mm out of the inner end
face of collar boss A (11A).
a When only a single crane is used, stop
slinging of the mounting pin with the
crane and remove the belt before-
hand.
WA1200-6 50-375
Work equipment
9. Final center alignment of collars A and B and 5) Perform center alignment of collars A (11)
bushing and B (12) with bushing (13) placing a person
1) When installing mounting pin (10), to prevent for confirming the center alignment in a posi-
collar B (12) from being moved to the outside tion opposite to mounting pin (10) installation
by mounting pin (10), install any of the collar side (collar B (12) side).
stopper plates of special tool T10, T11, or k Use a rod and such for this center
T12 to collar B (12) using tool T14 bolt. Then alignment. Be sure not to insert your
install tool T13 bolt. fingers into the holes.
q Tool T10: For pin of f180 mm 6) After checking that collars A (11) and B (12)
q Tool T11: For pin of f240 mm do not touch bushing boss (13A), push
q Tool T12: For pin of f280 mm collars A (11) and B (12) toward bushing (13)
a There are three approaches, A, B and C with your hands.
types, in installing the collar stopper plate a Push them carefully so that bushing seal
of tools T10, T11 and T12. For details, assembly (14) are not out of position.
see "4. Attached tools (collar stopper 7) Push collar B (12) using tool T13 bolt.
plate) installation procedure (T10, T11
and T12)" in "How to use special tools".
2) To prevent bushing seal assembly (14)
installed to respective collars A (11) and B
(12) from touching bushing boss (13A) when
the boss is installed, position collars A (11)
and B (12) outside respective collar bosses A
(11A) and B (12A) in advance.
3) Keep tool T13 bolt lightly contacting collar B
(12).
a Tighten tool T13 bolt so that bushing seal
assembly (14) on collar B (12) dose not
touch bushing boss (13A) when the boss
is installed.
4) Sling bushing boss (13A) using a crane and
8) Supply a large volume of gear oil to busing
install it between collar boss A (11A) and B
(13) and collar B (12) using cups [2], then
(12A).
apply a large volume of oil to entire inner
surfaces of bushing (13) and collar B (12)
with your hands.
a Prepare two plastic cups of approximately
500 cc.
a Apply oil heavily to the upper inner face of
the bushing.
a Do not use a brush since its bristles can
adhere to the surface.
2 Collars B and bushing (inner
surface):
Gear oil (GL-5)
Purpose: Thickness of film of the gear oil
applied to mounting pin (10) is
reduced by the dust seal and collar
O-ring on collar A (11) when the
mounting pin is installed. There-
fore, applying a large volume of
gear oil to the bushing immediately
before the mounting pin is installed
allows the gear oil initially applied
on the pin to form an oil film
between the installed mounting pin
and bushing.
50-376 WA1200-6
Work equipment
After a large volume of gear oil is applied
a Do not strike mounting pin (10) with a

hammer to insert. You must refrain from
10. Final installation of pin such practice to prevent detachment of
1) Check the center alignment again to make bushing seal (14), that is installed to collar
sure that the center of bushing boss (13A) A (11) and B (12), and forcible insertion of
and that of collars A (11) and B (12) are not the mounting pin.
misaligned. a If mounting pin (10) is stopped halfway
k Whenever center alignment is needed, through bushing (13) and remains there
use a rod and such without inserting immovable with hands, align the center of
your fingers into the holes. collar B (12) and bushing (13) using the
2) Push mounting pin (10) at a breath until it crane without trying to forcibly inserting it
passes collar O-ring (16) and dust seal (15) by use of a special tool. Then insert the
of collar B (12). mounting pin with hands again.
a Dust seal (15) is installed to the machine a When you pull mounting pin (10) out of
with serial number 50077 and up. bushing (13) once to align the center of
a Install mounting pin (10) with its oil holes collars A (11) and B (12) with bushing
(f) in vertical direction. (13), collar A (11) may move to the out-
a When diameter of the mounting pin is side along with the movement of mount-
large (240 or 280 mm), it must be pushed ing pin (10) under the pulling force and, as
by a pair of workers from the start be- a result, detachment of bushing seal as-
cause it requires large insertion force. sembly (14) on collar A (11) from the
a If you stop insertion of mounting pin (10) groove can occur. Therefore, you must
halfway, center alignment is lost and the first prevent outward-movement of collar
pin insertion force can be increased. A (11) by fixing it with the pin flange fixing
Therefore, you must insert it at a breath at bolt and spacer and then pull out mount-
least up to a position near collar B (12) ing pin (10).
and O-ring (16). After that, insert the
mounting pin slowly using the pin flange
fixing bolt and spacer or using special tool
T3 (mounting pin insertion tool).
WA1200-6 50-377
Work equipment
Purpose: Travel of collar A is measured in the

above step 6-1) and the shims neces-
sary to adjust the clearance between
collar A (11) and bushing (13) based
on the travel are already determined in
the previous measurement in 7-11).
However, this re-measurement is
required to confirm that bushing seal
assembly (14) installed to collar A (11)
is not detached.
a In this case, measurement of the travel of
collar A is to measure its distance of pro-
trusion out of collar boss A. However,
since collar A is hidden by the flange of
the mounting pin and direct measurement
3) Fix mounting pin (10) using pin flange fixing
is unavailable. Therefore, the clearance
bolt (8) and spacer (9) securely.
between the mounting pin flange and the
4) Using tool T13, push collar B (12) toward
mounting surface on collar boss A is mea-
bushing (13) and fix it.
sured here by use of a feeler gauge. (In
most cases, the measurement is 0 mm.)
a Measurement of travel of collar A must be
done in the same position as that used in
the previous step 6-1).
a When the re-measurement shows that
collar A is 4 to 5 mm outside compared to
the measurement in the previous step
6-1), the bushing seal assembly installed
to collar A may be out of position, or dam-
aged. In this case, pull out the mounting
pin once and replace the bushing seal as-
sembly with a new one.
2 Bushing seal assembly:
Gear oil (GL-5)
5) Remove the belt of the crane slinging a After pulling out the mounting pin, repeat
bushing boss (13A). the work from step 9 "Final center align-
ment of collars A and B and bushing".
11. Measurement of the final travel of collars A and
B with respect to the mounting pin tip (final
measurement)
1) In order to reconfirm the travel, "dimension
a", of collar A (11), measure the travel of
collar A (11), "dimension a", with respect to
collar boss A (11A) again and note the
measurement in No.1.3 of Attached Table 1.
q Collar A is outside the end face of collar
boss A
: Record the value as "-a13 dimension".
q Collar A is inside the end face of collar
boss A
: Note the value as "+a23 dimension".
2) In order to recheck the travel, "dimension b"
of collar B (12), measure "dimension b", that
is the travel of collar B (12) with respect to
collar boss B (12A), again and note the
measurement in No.1.3 of Attached Table 1.
q Collar B is outside the end face of collar
boss B
: Note the value as "-b13 dimension".
50-378 WA1200-6
Work equipment
q Collar B is inside the end face of collar q When collar B (12) is inside collar boss B
boss B (12A)
: Note the value as "+b23 dimension".
Purpose: Although the travel of collar B (12)
is measured in the previous step 6-2),
this measurement is required to
confirm that the previous state is main-
tained and bushing seal assembly (14)
remains installed to collar B (12) in
position.
a Measurement of travel of collar B must be
done in the same position as that used in
the previous step 6-2).
a When the re-measurement shows that
collar B is 4 to 5 mm outside compared to
the measurement in the previous step
6-2), bushing seal assembly (14) installed
3) Measure "dimension c", that is the travel of
to collar B may be out of position or dam-
collar B (12) with respect to the tip of
aged. In this case, remove the tool (collar
mounting pin (10), and note it in No.1.3 of
stopper plate), pull out collar B and re-
Attached Table 1.
place the bushing seal assembly with a
a In order to avoid confusion in the mea-
new one.
2 Bushing seal assembly:
sured results, attach the travel symbols +
(plus) or - (minus) representing the travel
Gear oil (GL-5)
of collar B end face with respect to the
a Install collar B again slowly, install the tool
mounting pin end face (tip) to the mea-
(collar stopper plate) and, using tool T13
sured "dimension c" as shown below.
bolt, push collar B toward the bushing and
q When the end face of mounting pin is
fix it. Then measure travel of collar B
outside collar B:
again.
Note the value as "-c13 dimension".
a Result of the re-measurement conducted
q When the end face of mounting pin is
on the travel of collar B may deviate 1 to
inside collar B:
2 mm from the measurement in the previ-
Note the value as "+c23 dimension".
ous 6-2), but you can ignore it since the
Purpose: To determine the thickness of
deviation can be regarded as within the
the collar end face shims or pin end
measurement error. (In this case, the
face shims to be installed to collar
above value is used as the final "dimen-
B.
sion b".
a The above measurement must be done in
q When collar B (12) is outside collar boss
the same or near the position where mea-
B (12A)
surement of travel of collar B with respect
to the collar boss B, "dimension b" was
conducted.
q When tip of mounting pin is outside collar B
(12)
WA1200-6 50-379
Work equipment
q When tip of mounting pin is inside collar B 6) Select the types (collar end face shim, pin
(12) end face shim or both) and numbers of shims
necessary to approximate the thickness
calculated for collar B (12), and note them
including shim pack thickness in No.3.2.
a See Attached Tables 4-3 and 4-4.
13. Final installation of shims

1) Remove pin flange fixing bolts (8) and
spacers (9) once.
2) Remove tool T10, T11, or T12, T13 and T14
from collar boss B, and install tool T14 bolt to
tool T10, T11, or T12 to which it was origi-
nally installed.
a Do not leave the mounting bolt hole in
tools T10, T11 and T12 without the bolt
12. Calculation of necessary shim pack thickness
since the holes are rusted and eroded
based on each dimension measurement
and further use is disabled. Be sure to in-
a Calculate the necessary shim pack thickness
stall tool T14 (including washer) to them.
according to the following procedure so that
an appropriate clearance is secured between
bushing (13) and collars A (11) and B (12),
and note the types and numbers of selected
shims in Attached Table 2.
q Appropriate clearance between collars A,
B and bushing: 0.5 to 0.7 mm.
1) Check each measurement in Attached Table
1.
a Measurement result in Attached Table 1
indicates the degree of contact between
bushing (13) and collars A (11) and B
(12).
2) Calculate the shim pack thickness necessary
to secure an appropriate clearance between
collar A (11) and bushing (13), and note it in 3) Prepare shims necessary for collar A (11)
No.2.1 of Attached Table 2. and collar B (12), remove stains on them and
a See Attached Tables 4-1 and 4-2. apply a thin film of oil to them.
3) Determine the necessary numbers of pin a Prepare shims for the pin flange at this
flange shims from calculation of above 2) and point.
note it in No.2.2 of Attached Table 2. 4) Install shims to collar A (11) and pin flange
a Available thickness of the pin flange shim shims (30) to the flange of mounting pin (10)
is 0.5 mm alone. and fix them using pin flange fixing bolts (8)
a See Attached Tables 4-1 and 4-2. and spacers (9).
4) Assuming that shims are inserted to collar A a When the lift arm cylinder bottom is dis-
(11), re-calculate "dimension c", that is the connected from the front frame, install the
travel of the tip of mounting pin (10) with shims for the pin flange to the top and bot-
respect to collar B (12), and note it in No.3.1 tom in accordance with machined surface
of Attached Table 2. (1A) on the front frame. The positions of
a See Attached Tables 4-3 and 4-4. pin flange mounting bolts for front fame
5) Taking into consideration the mounting pin is (1) are the same in the top and bottom,
moved in above Step 4), calculate the thick- and right and left.
ness of shims for collar B (12) necessary to
secure an appropriate clearance between
collar B (12) and bushing (13), and note it in
No.3.2 of Attached Table 2.
a See Attached Tables 4-3 and 4-4.
50-380 WA1200-6
Work equipment
14. Installation of dirt intrusion prevention ring

a Install the dirt intrusion prevention ring in step
4 "Center alignment collars A and B and
bushing".
a Joint to which dirt intrusion prevention ring is
installed
q Joint between lift arm and bucket
1) Joint betweenlift arm and bucket
1] Install snap ring (22) to lift arm (1).
5) Install collar end face shim (31) or pin end

face shim (32) to collar B (12).
a In this case, when the collar end face
shim is used, install it to cover (19). And
when the pin end face shim (32) is used,
install it to the tip of mounting pin (10).
6) Clean stains off cover (19), apply gear oil to
cover O-ring (20) and install cover O-ring (20)
to cover (19) taking care not to twist the
O-ring.
2 Collar O-ring:
Gear oil (GL-5) 2] Place snap ring (22) in the snap ring
7) Install cover (19) to the tip of mounting pin groove on top and bottom dirt intrusion
(10), install cover mounting bolts (17) and prevention rings (21), and install top and
washer (18) and tighten them to the specified bottom dirt intrusion prevention rings (21)
torque. to lift arm (1).
8) Tighten pin flange fixing bolts (8) to the spec-
ified torque.
3 Pin flange fixing bolt
M24: 824 to 1,030 Nm {84 to 105
kgm}
M30: 1,520–1,910m {155–195 kgm}
WA1200-6 50-381
Work equipment
3] Connect top and bottom dirt intrusion 2) Joint between bell crank and bucket link and
prevention rings (21) using top and joint between bucket and bucket link
bottom ring fixing bolts (23) and tighten 1] Install snap ring (27) to bucket link (3).
the bolts to the specified torque. 2] Place snap ring (27) in the snap ring
3 Top and bottom ring fixing bolt: groove on dirt intrusion prevention ring
98 to 123 Nm {10.0 to 12.5 kgm} (26).
4] Install the bushing boss between the 3] Install the bushing boss between the
collar bosses and, after the center align- collar bosses and, after the center align-
ment is over, push dirt intrusion preven- ment is over, push dirt intrusion preven-
tion ring (21) toward the bucket side. tion ring (26) toward the bucket or bell
a After the installation is finished, install crank side.
ring horizontalization bolt (24) and a After the installation is finished, install
washer (25) and tighten it to the spec- ring horizontalization bolt (28) and
ified torque. washer (29) and tighten it to the spec-
3 Ring horizontalization bolt: ified torque.
98 to 123 Nm {10.0 to 12.5 kgm}
50-382 WA1200-6
Work equipment
15. Refilling of gear oil to work equipment pin 16. Installation of other work equipment joints
a High viscosity oil must be used in hot regions. a Perform installation of the remaining joints in
q See step 22 "Introduction of high viscosity the same procedure as described in steps 2
oils". to 15.
a Since high viscosity oil is hard and difficult to
supply warm it to soften before refilling. 17. Adjustment of lift arm levelness detection switch
a Since high viscosity oil is hard and oil level a Adjust the proximity switch. For details, see
does not become horizontal soon, you must Testing and adjusting, "Adjustment of lift arm
recheck the oil level again in about 8 hours levelness detection switch".
from the refilling.
1) Tighten lower gear oil drain plug (34) 18. Adjustment of lift arm potentiometer
installed to mounting pin (10) and remove a Adjust the lift arm potentiometer. For details,
upper gear oil filler plug (33). see Testing and adjusting, "Adjustment of lift
2) Supply gear oil from the oil filler plug hole arm potentiometer".
until oil flows out of the hole.
5 Mounting pin: 19. Refilling
Gear oil (GL-5) (refilling) a Start the engine, circulate hydraulic oil in hy-
3) Install oil filler plug (33) again. draulic cylinder, piping, and hoses, and sup-
4) Clean attached oil. ply oil through the hydraulic tank oil filler to
20. Air bleeding

21. Running in
see "Running-in procedure" and "Procedure
for running in lift arm pin".
22. Introduction of high viscosity oil
a The following introduces the work equipment
pin oil for hot regions that does not easily
cause scuffing.
q Viscosity of this oil is higher than that of
the normally used oil.
q Use of this oil is prohibited when ambient
temperature is below 5 °C because of its
high pour point.
q Other usages, replacement intervals and
amount of use are the same as that of the
standard oil.
q Oil part number: 42C-98-11220
q Volume per container of this part number
is 18 l and six containers in total are nec-
essary for a machine.
q And when ordering a machine that uses
the oil for hot regions, select the sales
code "6ZZ61A".
WA1200-6 50-383
Work equipment
Attached Table 1 Note for travel of collars A and B and mounting pin tip 50-384
a See Attached Tables 4-1 to 4-4.
Travel of collar A with respect to collar boss A Travel of collar B with respect to collar boss B
Moving
Moving
Outside distance Inside the Outside
No. Content distance Inside the
Display the collar from collar Display the collar
from inside collar boss
boss inside to boss boss
to outside
outside
1 Measurement indication -a1 +a2 -b1 +b2
Measurement (right
mm mm mm mm
6-1) and and left)
1.1
2) Before Measurement (top
(Step mm mm mm mm
pin inser- and bottom)
1)
tion -a11 mm -b11 mm
Mean
+a21 mm +b21 mm
An appropriate clearance between
0.5–0.7 mm
collars A, B and bushing
Numbers
of 0.5 mm pieces
Selection of shims shims
7-11)
for collar end face Numbers
Immedi-
1.2 when collar A is of 0.3 mm pieces
ately
(Step inside collar boss A shims
before
2) Total shim
pin inser- mm
thickness
tion
Travel after shims
for collar end face +a22 mm mm
are inserted to pin
Measurement (right
mm mm mm mm
11-1) and and left)
1.3
2) After Measurement (top
(Step mm mm mm mm
pin inser- and bottom)
3)
tion -a13 mm -b13 mm
Mean
+a23 mm +b23 mm
Travel of pin with respect to collar B

Moving dis-
No. Content Outside the tance from Inside the
Display
collar boss inside to collar boss
outside
1 Measurement indication -c1 +c2
Measurement
mm mm
11-3) (right and left)
After Measurement
1.3
pin (top and bot- mm mm
(3step)
inser- tom)
tion -c13 mm
Mean
+c23 mm
50-384 WA1200-6
Work equipment
Attached Table 2 Calculation of necessary shim thickness based on each dimension measurement 50-385
a See Attached Tables 4-1 to 4-4.
Travel of collar A with respect to collar boss A Travel of pin end face with respect to collar B
Moving dis- Moving
No. Content Outside the tance from Inside the Outside distance Inside the
Display Display
collar boss inside to collar boss the collar B from inside collar B
outside to outside
Calculation of shim thickness Appropriate clearance between collar A and
2
for pin flange bushing: 0.5 to 0.7 mm
12-2) A1 -a13 - 0.5
Theoretical calculation when
shims are not assumed in A2 +a23 - 0.5 +a23 - 0.5
2.1 No.1.3
12-2)
Calculation after shims are A1 or A2 +a22 - 0.5 +a22 - 0.5
inserted in No.1.2
The minimum thickness
Shim are
Precautions for selection of of shims for pin flange
not neces-
shims for pin flange that exceed A1 dimen-
sary
sion
2.2
12-3) Quantity of
0.5 mm pieces pieces
Final thickness of shims
shims for pin Total shim
A mm mm
flange thickness
Set an optimum clearance between
Calculation of shims for collar
0.5 and 0.7 mm first, then insert
3 B end face and shim thickness
shims for collar end face and shims
for pin end face
for pin flange.
=-c13 + A
12-4), 5) Theoretical calcula- c1
+ 0.5
3.1 tion
=-c13 + A =+c23 + A
c2
+ 0.5 + 0.5
The maximum thick- The minimum thickness
Precautions for selection of ness of collar end face of pin end face shims
shims for pin flange shims that does not that exceeds C2 dimen-
exceed C1 dimension sion
3.2
12-6) Types of Shim for collar end
Shim for pin end face
Final thickness of shims: face
collar end face Number of 0.3 mm pieces pieces pieces
shims and pin end shims 0.5 mm pieces pieces pieces
face shims Total shim thickness c mm mm mm
WA1200-6 50-385
Work equipment
Attached Table 3 Part numbers of shims used for each part 50-386
Pin diame- Shim thick-
Shim part number
Shim installation position ter ness Shim part number Shim part number
for pin flange
(mm) (mm) for collar end face for pin end face
0.5 42C-70-12920 42C-70-11880 42C-70-11840
Joint between lift arm and bucket f240
0.3 – 42C-70-11780 42C-70-11830
0.5 42C-70-12910 42C-70-11870 42C-70-11860
Joint between bucket and bucket link f180
0.3 – 42C-70-11770 42C-70-11850
0.5 42C-70-12910 42C-70-11870 42C-70-11860
Joint between bell crank and bucket link f180
0.3 – 42C-70-11770 42C-70-11850
Joint between bell crank and piston rod 0.5 42C-70-12910 42C-70-11870 42C-70-11860
f180
of bucket cylinder 0.3 – 42C-70-11770 42C-70-11850
Joint between bucket cylinder bottom 0.5 42C-70-12910 42C-70-11870 42C-70-11860
f180
and front frame 0.3 – 42C-70-11770 42C-70-11850
0.5 42C-70-11920 42C-70-11880 42C-70-11840
Joint between lift arm and bell crank f240
0.3 – 42C-70-11780 42C-70-11830
Joint between lift arm and piston rod of 0.5 42C-70-12920 42C-70-11880 42C-70-11840
f240
lift arm cylinder 0.3 – 42C-70-11780 42C-70-11830
Joint between lift arm cylinder bottom 0.5 42C-70-12930 42C-70-11880 42C-70-11840
f240
and front frame 0.3 – 42C-70-11780 42C-70-11830
0.5 42C-70-12940 42C-70-11890 42C-70-11820
Joint between lift arm and front frame f280
0.3 – 42C-70-11790 42C-70-11810
50-386 WA1200-6
Work equipment
Attached Table 4-1 Selection of shims for collar A side (pin flange side) collar end face 50-387
1.1 (1 step), 6-1 and 2) 1.2 (2 step), 7-11) Remarks
Shim thickness on collar A side (shim for collar
Travel of collar A with respect to After shims are Appropriate clearance between
end face)
collar boss A (before pin inser- inserted collar A and bushing: 0.5 to 0.7
Number of
tion) Type Total thickness (+a22) mm.
shims
-0.7 mm -0.7 mm
-0.6 mm -0.6 mm
-0.5 mm -0.5 mm
-0.4 mm -0.4 mm
–a11 See Fig. 1
-0.3 mm -0.3 mm
-0.2 mm -0.2 mm
-0.1 mm -0.1 mm
0 mm 0 mm
+0.1 mm +0.1 mm
+0.2 mm +0.2 mm
+0.3 mm 0.3 mm 1 0.3 mm 0 mm
+0.4 mm 0.3 mm 1 0.3 mm -0.1 mm
+a21 +0.5 mm +0.5 mm See Fig. 2
+0.6 mm +0.6 mm
+0.7 mm +0.7 mm
+0.8 mm 0.3 mm 1 0.3 mm +0.5 mm
+0.9 mm 0.3 mm 1 0.3 mm +0.6 mm
Fig. 1 Fig. 2
WA1200-6 50-387
Work equipment
Attached Table 4-2 Selection of shims for pin flange 50-38

1.3 (3 step), 11-1) and 2) Remarks
Collar A side shim thickness Clearance
Targeted shim
Measured travel of collar (shims for pin flange) after shims Appropriate clear-
Appropri- thickness Pin mov-
A with respect to collar are inserted ance between col-
ate clear- = -a13 - 0.5 ing dis-
boss A Number of Total thick- (between lar A and bushing:
ance or Type tance
(after pin insertion) shims ness collar A and 0.5 to 0.7 mm.
=+a23 - 0.5
bushing)
-0.9 mm 0.5 mm (-1.4 mm) 0.5 mm 3 1.5 mm 0.6 mm 0.6 mm
-0.8 mm 0.5 mm (-1.3 mm) 0.5 mm 3 1.5 mm 0.7 mm 0.7 mm
-0.7 mm 0.5 mm (-1.2 mm) 0.5 mm 3 1.5 mm 0.8 mm 0.8 mm
-0.6 mm 0.5 mm (-1.1 mm) 0.5 mm 3 1.5 mm 0.9 mm 0.9 mm
-0.5 mm 0.5 mm (-1.0 mm) 0.5 mm 2 1.0 mm 0.5 mm 0.5 mm
–a13 See Fig. 3
-0.4 mm 0.5 mm (-0.9 mm) 0.5 mm 2 1.0 mm 0.6 mm 0.6 mm
-0.3 mm 0.5 mm (-0.8 mm) 0.5 mm 2 1.0 mm 0.7 mm 0.7 mm
-0.2 mm 0.5 mm (-0.7 mm) 0.5 mm 2 1.0 mm 0.8 mm 0.8 mm
-0.1 mm 0.5 mm (-0.6 mm) 0.5 mm 2 1.0 mm 0.9 mm 0.9 mm
0 mm 0.5 mm (-0.5 mm) 0.5 mm 1 0.5 mm 0.5 mm 0.5 mm
+0.1 mm 0.5 mm (-0.4 mm) 0.5 mm 1 0.5 mm 0.6 mm 0.5 mm
+0.2 mm 0.5 mm (-0.3 mm) 0.5 mm 1 0.5 mm 0.7 mm 0.5 mm
+0.3 mm 0.5 mm (-0.2 mm) 0.5 mm 1 0.5 mm 0.8 mm 0.5 mm
+a23 +0.4 mm 0.5 mm (-0.1 mm) 0.5 mm 1 0.5 mm 0.9 mm 0.5 mm See Fig. 4
+0.5 mm 0.5 mm (0 mm) – – 0 mm 0.5 mm 0 mm
+0.6 mm 0.5 mm (+0.1 mm) – – 0 mm 0.6 mm 0 mm
+0.7 mm 0.5 mm (+0.2 mm) – – 0 mm 0.7 mm 0 mm
Fig. 3 Fig. 4
50-388 WA1200-6
Work equipment
Attached Table 4-3 Selection of shims for collar B side (shims for pin end face) collar end face 50-389
1.3 (3 step), 11-3) Remarks
Shim thickness on collar B side Clearance
(shim for collar end face) after shims
Appropriate
Appro- Targeted thickness (shim for pin end face) are
Measured pin tip clearance
priate after pin is moved Shim for collar end face inserted
dimension that is between collar B
clear- =- c13 + 0.5 + A (between
outside the collar B Total and bushing:
ance (* When A = 0 mm) Number Number collar B
Type Type thickness 0.5 to 0.7 mm.
of shims of shims and bush-
ing)
-1.7 mm 0.5 mm -1.2 mm 0.3 mm 4 – 1.2 mm 0.5 mm
-1.6 mm 0.5 mm -1.1 mm 0.3 mm 2 0.5 mm 1 1.1 mm 0.5 mm
-1.5 mm 0.5 mm -1.0 mm – 0.5 mm 2 1.0 mm 0.5 mm
-1.4 mm 0.5 mm -0.9 mm 0.3 mm 3 – 0.9 mm 0.5 mm
-1.3 mm 0.5 mm -0.8 mm 0.3 mm 1 0.5 mm 1 0.8 mm 0.5 mm
-1.2 mm 0.5 mm -0.7 mm 0.3 mm 2 – 0.6 mm 0.6 mm
-1.1 mm 0.5 mm -0.6 mm 0.3 mm 2 – 0.6 mm 0.5 mm See Fig. 5
-1.0 mm 0.5 mm -0.5 mm – 0.5 mm 1 0.5 mm 0.5 mm
-0.9 mm 0.5 mm -0.4 mm 0.3 mm 1 0.3 mm 0.6 mm
-0.8 mm 0.5 mm -0.3 mm 0.3 mm 1 0.3 mm 0.5 mm
-0.7 mm 0.5 mm -0.2 mm – – 0 mm 0.7 mm
-0.6 mm 0.5 mm -0.1 mm – – 0 mm 0.6 mm
-0.5 mm 0.5 mm 0 mm – – 0 mm 0.5 mm
-c13 Shim for pin end face Clearance
after shims
are
Total inserted
– – – Number Number
Type Type thickness (between
of shims of shims
collar B
and bush-
ing)
-0.4 mm 0.5 mm +0.1 mm 0.3 mm 1 0.3 mm 0.7 mm
-0.3 mm 0.5 mm +0.2 mm 0.3 mm 1 0.3 mm 0.6 mm
-0.2 mm 0.5 mm +0.3 mm 0.3 mm 1 0.3 mm 0.5 mm
-0.1 mm 0.5 mm +0.4 mm 0.5 mm 1 0.5 mm 0.6 mm
0 mm 0.5 mm +0.5 mm 0.5 mm 1 0.5 mm 0.5 mm
*A: Dimension A indicates thickness of shims for flange. The value shown here is the one when shims are not
inserted. When they are inserted, add the thickness of inserted shims.
Fig. 5
WA1200-6 50-389
Work equipment
Attached Table 4-4 Selection of shims for pin end face 50-390
1.3 (3 step), 11-3) Remarks
Shim thickness on collar B side Clearance after Appropriate
Targeted thickness
Measured pin tip Appropri- (shim for pin end face) shims are clearance
after pin is moved
dimension that is ate clear- Num- inserted between collar B
= +c23 + 0.5 + A Number Total
outside the collar B ance Type Type ber of (between collar and bushing: 0.5
(* When A = 0 mm) of shims thickness
shims B and bushing) to 0.7 mm.
+0.1 mm 0.5 mm +0.6 mm 0.3 mm 2 0.6 mm 0.5 mm
+0.2 mm 0.5 mm +0.7 mm 0.3 mm 1 0.5 mm 1 0.8 mm 0.6 mm
+0.3 mm 0.5 mm +0.8 mm 0.3 mm 1 0.5 mm 1 0.8 mm 0.5 mm
+0.4 mm 0.5 mm +0.9 mm 0.3 mm 3 0.9 mm 0.5 mm
+0.5 mm 0.5 mm +0.10 mm 0.5 mm 2 1.0 mm 0.5 mm
+0.6 mm 0.5 mm +0.11 mm 0.3 mm 2 0.5 mm 1 1.1 mm 0.5 mm
+0.7 mm 0.5 mm +0.12 mm 0.3 mm 1 0.5 mm 2 1.3 mm 0.5 mm
+0.8 mm 0.5 mm +0.13 mm 0.3 mm 1 0.5 mm 2 1.3 mm 0.6 mm
+0.9 mm 0.5 mm +0.14 mm 0.3 mm 3 0.5 mm 1 1.4 mm 0.5 mm
+0.10
0.5 mm +0.15 mm 0.5 mm 3 1.5 mm 0.5 mm
+c23 mm See Fig. 6
+0.11
0.5 mm +0.16 mm 0.3 mm 2 0.5 mm 2 1.6 mm 0.5 mm
mm
+0.12
0.5 mm +0.17 mm 0.3 mm 1 0.5 mm 3 1.8 mm 0.6 mm
mm
+0.13
0.5 mm +0.18 mm 0.3 mm 1 0.5 mm 3 1.8 mm 0.5 mm
mm
+0.14
0.5 mm +0.19 mm 0.3 mm 3 0.5 mm 2 1.9 mm 0.5 mm
mm
+0.15
0.5 mm +0.20 mm 0.5 mm 4 2.0 mm 0.5 mm
mm
*A: Dimension A indicates thickness of shims for flange. The value shown here is the one when shims are not
inserted. When they are inserted, add the thickness of inserted shims.
Fig. 6
50-390 WA1200-6
Work equipment
Procedure for running in bucket pin
Procedure for running in bucket pin 50-391
q When disassemble or assemble the work equip- 3. Run the engine at low idle, and set cutting edge
ment, or removing or installing it, perform run- (1) of the bucket horizontal. Tilt the bucket
ning-in operation of the bucket pin and lift arm approx. 35 degrees up (approx 10 degrees
pin. before the tilt back stroke end), return it to hori-
a For running-in operation of lift arm pin, see zontal, tilt it approx. 35 degrees down (approx
"Procedure for running in lift arm pin". 10 degrees before the dump stroke end), and
a Air must be bled from each cylinder before in- return it to horizontal. Repeat this cycle five
stalling the work equipment assembly. times.
1. Run the engine at low idle, and set cutting edge

(1) of the bucket horizontal. Tilt the bucket
approx. 10 degrees up, return it to horizontal, tilt
it approx. 10 degrees down, and return it to hori-
zontal. Repeat this cycle five times.
4. Run the engine at low idle, and tilt the bucket

from the tilt back stroke end to dump stroke end.
Repeat this cycle five times.
2. Run the engine at low idle, and set cutting edge

(1) of the bucket horizontal. Tilt the bucket
5. Run the engine at 1500 rpm, and set cutting

edge (1) of the bucket horizontal. Tilt the bucket
WA1200-6 50-391
Work equipment
Procedure for running in bucket pin
8. Run the engine at 1500 rpm, and tilt the bucket

from the tilt back stroke end to dump stroke end.
Repeat this cycle five times.
Make the bucket cylinder hydraulic stall five
times at its stroke end.
6. Run the engine at 1500 rpm, and set cutting

9. Run the engine at full speed, and set cutting
approx. 35 degrees up (approx 10 degrees
before the tilt back stroke end), return it to hori-
zontal, tilt it approx. 35 degrees down (approx
10 degrees before the dump stroke end), and
return it to horizontal. Repeat this cycle five
times. During the operation, Move the bucket
cylinder slowly to its stroke end and make the
cylinder hydraulic stall five times.
a Check that each pin is free from oil leakage,

creak, and heat. If any abnormality found,
disassemble the unit, isolate the cause, and
7. cutting edge (1) of the bucket horizontal. Tilt the take proper actions.
bucket approx. 35 degrees up (approx 10 a Oil used for lubricated pin
degrees before the tilt back stroke end), return it q Quality: API.GL-5
to horizontal, tilt it approx. 35 degrees down q Viscosity: SAE80W-90
(approx 10 degrees before the dump stroke q Operating temperature range: -30 °C to
end), and return it to horizontal. Repeat this +50 °C

cycle five times. q Total oil capacity: 86 l
50-392 WA1200-6
Work equipment
Procedure for running in lift arm pin
Procedure for running in lift arm pin 50-393
q When disassemble or assemble the work equip- 3. Run the engine at low idle, and move the work
ment, or removing or installing it, perform run- equipment up and down five times from a posi-
ning-in operation of the lift arm pin and bucket tion where bucket (1) is on the ground to a posi-
pin. tion where lift arm cylinder (5) is approx. 100 mm
a For running-in operation of bucket pin, see before its stroke end.
"Procedure for running in bucket pin". a A position where the lift arm is approx. 40 de-
a Air must be bled from each cylinder before in- grees up from the horizontal.
stalling the work equipment assembly.
1. Run the engine at low idle, and move the work

equipment up and down five times from a posi-
tion where bucket (1) is on the ground to a posi-
tion where lift arm (2) is horizontal.
a Target of horizontal work equipment is that
lift arm pin (3) on the frame side and bucket
pin (4) are horizontally aligned.

tion where lift arm cylinder(5) is at its stroke end
(lift arm stroke end).
a A position where the lift arm is approx. 46 de-
grees up from the horizontal.

tion where lift arm (2) is approx. 25 degree up
from the horizontal.
a Target of 25-degree up work equipment is
that bucket pin (4) and the operator's eyes
are horizontally aligned.
a When lift arm cylinder (5) reaches to its mini-

mum stroke, press bucket (1) against the
ground and lower lift arm (2) until front wheel
(6) is raised off the ground.
WA1200-6 50-393
Work equipment
7. Run the engine at 1500 rpm, and move the work

tion where lift arm cylinder (5) is approx. 100 mm
before its stroke end.
grees up from the horizontal.

tion where lift arm (2) is horizontal.
a Target of horizontal work equipment is that
lift arm pin (3) on the frame side and bucket
pin (4) are horizontally aligned.
tion where lift arm cylinder (2) is at its stroke end
(lift arm stroke end).
a Make the lift arm cylinder hydraulic stall at its
stroke end.
grees up from the horizontal

tion where lift arm (2) is approx. 25 degree up
from the horizontal.
a Target of 25-degree up work equipment is
that bucket pin (4) and the operator's eyes
are horizontally aligned.
a When lift arm cylinder (5) reaches to its mini-

mum stroke, press bucket (1) against the
ground and lower lift arm (2) until front wheel
(6) is raised off the ground.
50-394 WA1200-6
Work equipment
9. Run the engine at full speed, and move the work

tion where bucket(1) is on the ground to a posi-
tion where lift arm cylinder (2) is approx. 100
mmbefore its stroke end (lift arm is approx. 40
degrees up from the horizontal). During the
operation, move the lift arm cylinder slowly to its
stroke end and make it hydraulic stall.
a Check that each pin is free from oil leakage,

squeak, and heat. If any abnormality found,
disassemble the unit, isolate the cause, and
take proper actions.
a Oil used for lubricated pin
q Quality: API and GL-5
q Viscosity: SAE80W-90
q Operating temperature range: -30 °C to
+50 °C
q Total oil capacity: 86 l
WA1200-6 50-395
Cab
Removal and installation of bulkhead assembly
Cab 50-396
Removal and installation of bulkhead assembly 50-396
Removal 50-396 4. Disconnect harness connectors B06 (2), B07

k Before performing removal, be sure to imple- (3), B08 (4) and B09 (5), and disconnect wiring
ment "2. Preparatory work" and "3. Precau- harness (6).

"Removal and installation of hood assembly".
2. Remove the right handrail.
3. Remove all of partition covers (1).
5. Loosen clamps and remove hoses (7) and (8).
50-396 WA1200-6
Cab
Removal and installation of bulkhead assembly
6. Remove brackets (9), (10), (11), and (12). Installation 50-397

q Perform installation in the reverse order to the
7. Loosen hose clamps and remove tubes (13) and removal.
(14).
k When partition covers are removed, be sure
8. Loosen hose clamps and remove tubes (15) and to replace consumable parts as they are im-
(16). [*1] portant as fire prevention covers.
9. Disconnect the battery cable bracket. [*1]

3 Hose clamp:
10. Disconnect hose, tube, and wiring harness 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
connectors (ETH1 and ETH39) for the ether start
aid cartridge. [*2]
3 Bulkhead mounting bolt:
11. Loosen hose clamps and remove hoses (17) 157 to 196 Nm {16 to 20 kgm}
and (18).
12. Remove four air cleaner assemblies (19).
13. Sling bulkhead assembly (20), remove mounting

bolts, and then remove the bulkhead assembly.
[*2]
4 Bulkhead and air cleaner assembly:
720 kg
WA1200-6 50-397
Cab
Removal and installation of operator's cab and floor assembly
Removal and installation of operator's cab and floor assembly 50-398
Removal 50-398 9. Remove covers (3) and (4).
k Before performing removal, be sure to imple- 10. Remove condenser top cover (5).
necting and connecting hoses and tubes in
tice".
1. Lift and remove handrail (1).
2. Sling cover (2), remove 16 mounting bolts, and

then remove the cover.
3. Remove seven mounting bolts for cover (2a),

and sling cover (2a).
11. Disconnect antenna wiring harness connector
C25.
4. Remove the seven mounting bolts, and then
remove cover (2a).
12. Sling ROPS (6), remove mounting bolts, and
then remove the ROPS. [*1]
4 ROPS:
5. Sling cover (2b), remove five mounting bolts,
and then remove the cover.
3,240 kg
6. Sling cover (2c), remove five mounting bolts,
and then remove cover (2c).
7. Remove the cover on the left side in the same

way.
8. Remove the wiring clamps and hose clamps,

and then lift and remove the frame.
50-398 WA1200-6
Cab
13. Disconnect air conditioner hoses (8) and (9).[*2]
14. Disconnect air conditioner heater hoses (15) and

(16).
18. Disconnect hoses (14a) and (14b) for the

steering lock.
15. Disconnect wiring harness connectors FR1(51),

FL1(52), FL2(53), FR2(54), LR10(55),
LR11(56), LR12(57), LR1(58), L16(OP)(59),
LR2(60), and LR3(61).
16. Disconnect wiring harness connectors LR4(62),

LR5(63), LR6(64), LR7(65), LR8(66), and
LR9(67).
17. Disconnect wiring harness GND(68).
19. Disconnect hoses (23), (24), (25), (26), and (27)

for the pilot valve.
WA1200-6 50-399
Cab
20. Disconnect hose (28). 23. Remove four cab mounting nuts (31). [*3]
21. Disconnect joint (29). 24. Sling and remove operator's cab and floor
assembly (32).
a When removing the cab and floor assembly,
4 Operator's cab and floor assembly:
540 kg
22. Disconnect washer hoses (30).
50-400 WA1200-6
Cab
Installation 50-401

moval.
[*1]
3 ROPS mounting bolt:
5,000 ± 10% Nm {510 ± 10% kgm}
[*2]
2 O-ring (on flange connection):
Apply compressor oil (ND-OIL8) for the
new type refrigerant.
q Precautions for charging air conditioner with

refrigerant
k Ask a qualified person for collecting, add-
ing and filling operation of refrigerant
(R134a).
1) Keep the room temperature at 3 °C or higher.
(the system will not operate at temperatures
below 3 °C.)
2) Use R134a refrigerant.
3) Before charging the system with refrigerant,
evacuate the system thoroughly by repeat-
edly applying vacuum to the system.
(Vacuum must reach at least –100 kPa {-750
mmHg}.)
4) Rough standard for the refrigerant refill
capacity is 1.3 to 1.5 kg.
5) Be careful not to make mistakes, such as
turning the refrigerant can upside down, as
this may prevent liquid Freon from entering
the refrigeration system.
6) Do not let the compressor operate before
refilling refrigerant.
[*3]
3 Operator's cab and floor mounting bolt
nut:
245 to 309 Nm {25.0 to 31.5 kgm}
WA1200-6 50-401
Cab
Removal and installation of operator's cab assembly
Removal and installation of operator's cab assembly 50-402
Removal 50-402 4. Disconnect wiring harness connectors CL2(21),

CL3(22), M01A(23), CL1(24), FCL1(25), and
k Before performing removal, be sure to imple- FCL2(26).
1. Remove the ROPS. For details, see "Removal

and installation of operator's cab and floor
assembly".
2. Remove the side cover from the lower part of the

cab.
3. Disconnect three washer hoses (1) in the cab.
50-402 WA1200-6
Cab
5. Disconnect wiring harness connectors Installation 50-403

FC18(27), FC19(28), and FC20(29).
moval.
q Refilling of washer fluid

Replenish washer fluid to the washer tank to the
specified level.
6. Remove mounting bolts for operator's cab

assembly (3). Slowly lift and remove the oper-
ator's cab assembly.
a When removing the operator's cab assembly,
4 Operator's cab assembly:
590 kg
WA1200-6 50-403
Cab
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner unit assembly 50-404
Removal 50-404 4. Remove case (2).

ment "2. Preparatory work", "3. Precautions 5. Remove covers (3), (4), (5), and (6).
necting and connecting hoses and tubes in 6. Remove console box (7).
tice".
1. Remove the ROPS. For details, see "Removal

and installation of operator's cab and floor frame
assembly".
2. Remove the operator's cab assembly. For

details, see "Removal and installation of oper-
ator's cab assembly".
3. Remove the mounting bolts, and then lift and

remove operator's seat assembly (1).
4 Operator's seat assembly:
7. Disconnect wiring harness connectors CL2(8)
and CL3(9).
55 kg
8. Disconnect wiring harness clamps (10) and (11).
50-404 WA1200-6
Cab
9. Disconnect heater hoses (17) and (18). Installation 50-405
10. Disconnect air conditioner hoses (19) and (20). q perform installation in the reverse order to the re-
[*1] moval.
11. Remove the mounting bolts for air conditioner [*1]

unit assembly (21), and then lift and remove the 2 O-ring (on flange connection):
air conditioner unit assembly. Apply compressor oil (ND-OIL8) for the
4 Air conditioner unit assembly: new refrigerant.
55 kg
q Precautions for charging air conditioner with
refrigerant
k Ask a qualified person for collecting, add-
ing and filling operation of refrigerant
(R134a).
1) Keep the room temperature at 3 °C or higher.
(Because the system does not operate at
temperatures below 3 °C.)
2) Use R134a refrigerant.
3) Before charging the air conditioner with
refrigerant, evacuate the system thoroughly
by repeatedly applying vacuum operation to
the system.
(Vacuum must reach at least -100 kPa {-750
mmHg}.)
4) Rough charging amount of the refrigerant
refill capacity is 1.3 to 1.5 kg.
5) Be careful not to make mistakes, such as
turning the refrigerant can upside down, as
this may cause liquid Freon entering the
refrigeration system.
6) Do not let the compressor operate before
refilling refrigerant.
WA1200-6 50-405
Cab
Disassembly and assembly of operator seat
Disassembly and assembly of operator seat 50-406
[Manufactured by GRAMMER] 2. Removal and installation of seat cushion and

a The operator seat is not equipped with right and backrest cushion
left armrests. The disassembling and assem-
bling procedures for any components other than
the armrests are the same.
I. Upper seat 50-406

1. Removal and installation of document box
Removal
1) Remove the document box. For details, see
"1. Removal and installation of document
box".
2) Remove four screws (1) and remove back-
rest cushion (2).
Removal 3) Remove five screws (4) and remove seat
1) Open document box (1). cushion (5).
2) Remove hook (3). 4) Disconnect connectors (3) and (6).
3) Remove screws (2) and remove document
box (1). Installation
1) Connect connectors (3) and (6).
Installation 2) Install seat cushion (5) with five mounting
1) Install document box (1) and secure it with screws (4).
mounting screws (2). 3) Install backrest cushion (2) with four
2) Install hook (3). mounting screws (1).
4) Install the document box. For details, see "1.
Removal and installation of document box".
50-406 WA1200-6
Cab
3. Removal and installation of lumber support 4. Removal and installation of armrests

(For a machine equipped with armrests)
Removal
1) Remove the document box. For details, see Removal
"1. Removal and installation of document 1) Remove cover (1).
box". 2) Remove nut (2) and washer (3).
2) Remove the backrest cushion. For details, 3) Remove armrest (4).
see "2. Removal and installation of seat
cushion and backrest cushion". Installation
3) Hollow the head of rivet (1) using a drill and 1) Set armrests (4).
remove spring plate (2) from lever (3). 2) Install washer (3) and secure it with nut (2).
4) Remove lever (3) from catch element (4). 3 Mounting nut:
5) Remove bolt (5) and remove knob (6) and 25 Nm {2.6 kgm}
gear (7). 3) Install cover (1).
6) Hollow the head of rivet (8) and remove wrap
spring brake (9) and catch element (4).
Installation
1) Install wrap spring brake (9) and catch
element (4) and secure them with rivet (8).
2) Install knob (6) and gear (7) and secure them
with bolt (5).
3) Install lever (3) to catch element (4) and
secure the top of clamping lever (3) with rivet
(1).
4) Install two spring plates (2) to lever (3) and
secure the right side of them with rivet (1).
5) Install the backrest cushion. For details, see
"2. Removal and installation of seat cushion
and backrest cushion".
WA1200-6 50-407
Cab
5. Removal and installation of backrest
Removal Installation
1) Remove the document box. For details, see 1) Install bearing (8) and spring (9) to backrest
"1. Removal and installation of document (1).
box". a Apply non-acidic multi-purpose grease to
2) Remove the backrest cushion. For details, the surface where (Q) of backrest (1)
see "2. Removal and installation of seat come into contact with bearing (8).
cushion and backrest cushion". a Put bearing (B/8) into back support (B/4).
3) Disassemble the recliner. For details, see "6. 2) While gently pushing backrest (1) to the left,
Disassembly and assembly of recliner". install it upward.
4) Disassemble the recliner. For details, see "6. a Move the recliner until cylindrical protrud-
Disassembly and assembly of recliner". ing portion (C/2) fits into the positioning
5) Remove nut (5) and washers (6) and (7). hole in backrest support (C/3) on the left
6) Remove bolt (11) and washer (10). side.
7) While gently pushing backrest (1) to the left, a Engage spring (A/9) on the stopper weld-
remove it upward. ed to the backrest (A/1).
8) Remove bearing (8) and spring (9) from 3) Install washer (10) and bolt (11).
backrest (1). 4) Install washers (6) and (7) and secure them
with nuts (5).
3 Mounting nut:
25 Nm {2.6 kgm}
5) Assemble the recliner. For details, see "6.
Disassembly and assembly of recliner".
6) Install the armrests. For details, see "4.
Removal and installation of armrests". (For a
machine equipped with armrests)
50-408 WA1200-6
Cab
Assembly
6. Disassembly and assembly of recliner 1) Tilt backrest (1) forward.
2) Install handle (6) and lever (5).
3) Install screw (4), adapter plate (3), and screw
(2) in that order.
a Install screw (4) so that it fits to the notch
in adapter plate (3).
3 Mounting bolt:
12 Nm {1.2 kgm}
4) Install the armrests. For details, see "4.
Disassembly Removal and installation of document box".
1) Remove the document box. For details, see
"1. Removal and installation of document
box".
2) Remove the backrest cushion. For details,
see "2. Removal and installation of seat
cushion and backrest cushion".
3) Remove the armrests. For details, see "4.
4) Tilt backrest (1) forward.
5) Remove screw (2), adapter plate (3), and
screw (4) in that order.
6) Remove lever (5) and handle (6).
WA1200-6 50-409
Cab
7. Disassembly and assembly of seat angle and

height adjustment levers
2] Detach flexible support plate (7) from the

lock and lift it toward the back to remove
it.
4) Remove plate (15) according to the following
procedure.
1] Cut off rivet (22) and remove spring plate
(5).
2] Remove screw (8) and disassemble
cover (9), levers (6) and (10), link rod (11)
and lock lever (12).
3] Remove springs (13).
4] Turn lever (14) clockwise as far as it will
go. Pull plate (15) toward you and raise
and remove it.
5) Remove the right and left covers. For details,
see "8. Removal and installation of cover".
Disassembly 6) Remove nut (16), lever (14) and screw (17).
1) Remove the seat cushion. For details, see "2. 7) Cut off rivet (18) and remove spring sheet
Removal and installation of seat cushion and (19).
backrest cushion". 8) Cut off rivet (20) and remove notch plate (21).
2) Remove switch (4) according to the following
procedure.
(Only for a machine with a seat switch)
1] Remove springs (1).
2] Tilt switch plate (2) forward and remove it.
3] Cut off rivet (3) and remove switch (4).
3) Remove flexible support plate (7) according
1] While pushing (P) of spring seat (5)
inward (in the direction of an arrow), pull
up angle adjustment lever (6).
50-410 WA1200-6
Cab
Assembly
1) Install notch plate (21) to plate (15) and
secure it with rivet (20).
2) Install spring sheet (19) to plate (15) and
secure it with rivet (18).
3) Set lever (14), install screw (17) from the
underside and secure it with nut (16).
4) Install the right and left covers. For details,
see "8. Removal and installation of cover".
5) Assemble plate (15) according to the
1] Turn lever (14) clockwise and install plate
(15).
2] Fit one end of spring (13) to mounting
hole (a) in lever (14) and fit the other end
to mounting hole (b) in plate (15).
7) Install switch (4) according to the following

procedure.
(Only for a machine with a seat switch)
3] Secure lock lever (12), link rod (11), 1] Install switch (4) and secure it with rivet
levers (10) and (6), and cover (9) with (3).
mounting screws (8). 2] Tilt switch plate (2) forward and install it.
4] Install spring plate (5) and secure it with 3] Install springs (1).
rivet (22). 8) Install the seat cushion. For details, see "2.
6) Install flexible support plate (7) according to Removal and installation of seat cushion and
the following procedure. backrest cushion".
1] While pushing an area indicated by an
arrow (P) of spring seat (5) inward (in the
direction of an arrow), pull up angle
adjustment lever (6).
2] Install flexible support plate (7) to the
lock.
3] Fit one end of height adjustment link rod
(11) to mounting section (c) in lever (10)
and fit the other end to mounting bore (d)
in lever (14).
WA1200-6 50-411
Cab
8. Removal and installation of covers Installation

1) Install right and left covers (10).
2) Install washer (9) and secure it with rivet (8).
3) Turn lever (6) clockwise and install the plate.
4) Install springs (5). (See "7. Disassembly and
assembly of seat angle and height adjust-
ment levers".)
5) Install flexible support plate (4) according to
the following procedure. (See "7. Disas-
sembly and assembly of seat angle and
height adjustment levers".)
6) Install switch plate (2). (Only for a machine
with a seat switch)
7) Install springs (1). (Only for a machine with a
seat switch)
8) Install the seat cushion. For details, see "2.
Removal and installation of seat cushion and
backrest cushion".
Removal
1) Remove the seat cushion. For details, see "2.
backrest cushion".
2) Remove spring (1) and tilt switch plate (2)
forward and remove it. (Only for a machine
with a seat switch)
3) Remove flexible support plate (4) according
1] While pushing an area on the spring seat
indicated by an arrow inward, pull up
angle adjustment lever (3).
(See step 3) in "7. Disassembly and
assembly of seat angle and height adjust-
ment levers".)
2] Detach flexible support plate (4) from the
lock and lift it toward the back to remove
it.
4) Remove springs (5).
5) Turn lever (6) clockwise as far as it will go.
Pull plate (7) toward you and raise and
remove it.
6) Cut off rivet (8) and remove washer (9).
7) Pull right and left covers (10) toward you and
lift them up to remove them.
50-412 WA1200-6
Cab
9. Removal and installation of seat plate and slide Installation

rail 1) Install slide rail (10) to the suspension upper
seat.
2) Install nuts (9) and bolts (8).
a Replace the bolts with new ones.
3 Mounting bolt:
25 Nm {2.6 kgm}
3) Install boot to the suspension upper seat.
4) Install seat top assembly (1) and washer (7)
to slide rail (10) and slide them forward.
5) Set washer (5) and nut (6) and install bolt (4).
3 Mounting bolt:
25 Nm {2.6 kgm}
6) Slide seat top assembly (1) to the backward
end.
7) Set nut (3) and install bolt (2).
3 Mounting bolt:
25 Nm {2.6 kgm}
8) Install the seat cushion. For details, see "2.
backrest cushion".
Removal
1) Remove the seat cushion. For details, see "2.
backrest cushion".
2) Slide seat top assembly (1) to the backward
end.
3) Remove bolt (2) and nut (3).
4) Slide seat top assembly (1) to the forward
end.
5) Remove bolt (4), washer (5) and nut (6).
6) Remove seat top assembly (1) and washer
(7).
7) Move the boot from the suspension upper
seat downward.
8) Remove bolt (8) and nut (9).
9) Remove slide rail (10) from the suspension
upper seat.
WA1200-6 50-413
Cab
II Suspension 50-414
1. Removal and installation of upper cover 2. Removal and installation of front cover
Removal Removal
1) Remove the upper seat. For details, see "I 1) Remove the upper seat. For details, see "I
Upper seat". Upper seat".
2) Pull out power cable (3) from upper cover (2). 2) Remove the upper cover. For details, see "1.
3) Remove pin (1), then remove upper cover Removal and installation of upper cover".
(2). 3) Hollow out the head of rivet (1) and remove
cover (2).
Installation
1) Run power cable (3) through the hole in Installation
upper cover (2). 1) Install front cover (2) and secure it with rivet
2) Install upper cover (2) and secure it with (1).
mounting pin (1). 2) Install the upper cover. For details, see "1.
3) Install the upper seat. For details, see "I Removal and installation of upper cover".
Upper seat". 3) Install the upper seat. For details, see "I
Upper seat".
50-414 WA1200-6
Cab
3. Removal and installation of boot 5) Remove boot (5) from wire frame (2).
1) Remove the upper seat. For details, see "I 1) Install wire frame (5) to boot (2).
Upper seat". 2) Install boot (2).
2) Remove boot (2) from suspension upper part 3) Install the boot to suspension lower part (6) in
(1) according to the following procedure. the reverse order to removal.
1] Remove six pins (4) from the front of the 4) Secure the connector cable with cable ties
suspension upper part. (10). (For a machine equipped with a
2] Remove pin (3) from the left side of the connector cable)
suspension upper part. 5) Install the boot to suspension upper part (1)
3] Remove two pins (4) and two pins (3) in the reverse order to removal.
from the back of the suspension upper 6) Install the upper seat. For details, see "I
part. Upper seat".
4] Remove three pins (3) from the right side
of the suspension upper part and pull the
four mounting bolts and pull out the boot
above handle (9).
3) Disconnect boot (2) from suspension lower
part (6) according to the following procedure.
1] Remove three pins (3) from the front of
the suspension lower part.
2] Remove two pins (3) from the left side of
the suspension lower part.
3] Remove four pins (3) from the back of the
suspension lower part.
4] Remove cable tie (10) from the connector
cable on the right side of the suspension
lower part and remove two pins (3). (For
a machine equipped with a cable tie)
4) Raise and remove boot (2) from the suspen-
sion lower part.
WA1200-6 50-415
Cab
4. Removal and installation of damper adjustment wire and lever
Removal 10)Mark the locations where pull wire (5) is

1) Remove the upper seat. For details, see "I secured by cable ties (8) before removing
Upper seat". cable ties (8).
2) Remove the upper cover. For details, see "1. 11)Remove fixing cap (12) from damper (13).
Removal and installation of upper cover". 12)Remove pull wire (5) from bearing (9).
3) Remove the boot. For details, see "3. 13)Disassemble fixing cap (12) and fork (11).
Removal and installation of boot". 14)Remove pull wire (5) from fork (11) and
4) Raise the suspension to the uppermost level. remove fork (11) and spring (10).
k Raise the suspension taking care not 15)Mark the location of the hole in upper part (4)
to get your hand caught and secure it through which pull wire (5) is fed before
to prevent it from lowering by inserting removing the entire wire.
an appropriate spacer between the
swing arm mechanism and the lower
part.
5) Remove TORX screw (2).
6) Remove handle (1) from upper part (4).
7) Remove pull wire (5) from handle (1).
8) Pull out pull wire (5) downward from wire
bearing (6).
9) Hollow the head of rivet (7) and remove
bearing (6).
50-416 WA1200-6
Cab
Installation
a Secure the cable with cable ties to eliminate
slack.
1) Raise the suspension to the uppermost level.
k Raise the suspension taking care not
to get your hand caught.
a Secure the suspension to prevent it from
lowering by inserting an appropriate
spacer between the swing arm mecha-
nism and the lower part.
2) Feed pull wire (5) through the hole in upper
part (4) marked when removing the wire.
3) Attach pull wire (5) to fork (11) and spring
(10).
4) Assemble fixing cap (12) and fork (11).
5) Attach pull wire (5) to bearing (9).
6) Install fixing cap (12) to damper (13).
7) Install cable ties (8) to locations marked on
pull wire (5) when removing the cable ties.
a Route the wire as marked during removal.
8) Install bearing (6) and secure it with rivet (7).
9) Attach pull wire (5) to wire bearing (6).
10)Attach pull wire (5) to handle (1).
11)Install handle (1) to upper part (4).
12)Install TORX screw (2).
3 Mounting bolt:
2.25 Nm {0.23 kgm}
13)Install the boot. For details, see "3. Removal
and installation of boot".
14)Install the upper cover. For details, see "1.
Removal and installation of upper cover".
15)Install the upper seat. For details, see "I
Upper seat".
WA1200-6 50-417
Cab
5. Removal and installation of damper Installation

to get your hand caught.
a Secure the suspension to prevent it from
lowering by inserting an appropriate
spacer between the swing arm mecha-
nism and the lower part.
2) Install damper (4)
a Install the damper with the label facing
up.
3) Install stud (3) to swing arm (7) and damper
(4).
4) Install circlip (5) to stud (3).
a Apply non-acidic multi-purpose grease to
the entire surface (F) of stud (3).
5) Install fixing cap (2) and bearing (1) to
damper (4).
6) Install stud (6) to swing arm (7) and damper
(4).
the entire surface (F) of stud (6).
7) Install circlip (8) to stud (6).
8) Install the boot. For details, see "3. Removal
9) Install the upper cover. For details, see "1.
10)Install the seat cushion. For details, see "I
Upper seat".
Removal
1) Remove the seat cushion. For details, see "I
Upper seat".
2) Remove the upper cover. For details, see "1.
3) Remove the boot. For details, see "3.
Removal and installation of boot".
to get your hand caught and secure it
to prevent it from lowering by inserting
part.
5) Remove circlip (8) from stud (6).
6) Remove stud (6) from swing arm (7) and
damper (4).
7) Remove fixing cap (2) and bearing (1) from
damper (4).
8) Remove circlip (5) from stud (3).
9) Remove stud (3) from swing arm (7) and
damper (4).
10)Pull up and remove damper (4).
50-418 WA1200-6
Cab
6. Removal and installation of compressor
Removal 11)Remove compressor air hose (7) from

1) Remove the upper seat. For details, see "I compressor (3).
Upper seat". a Avoid using a screwdriver or similar tool
2) Remove the upper cover. For details, see "1. that may damage the hose when remov-
Removal and installation of upper cover". ing it from the compressor.
3) Remove the boot. For details, see "3. a Heating the end of hose by a hot air heat-
Removal and installation of boot". er will ease the removal.
4) Raise the suspension to the uppermost level. 12)Pull compressor (3) forward while pulling
k Raise the suspension taking care not compressor cable (5) downward.
to get your hand caught and secure it 13)Remove support (9) from suspension upper
to prevent it from lowering by inserting part (2).
part.
5) Mark the locations where compressor cable
(5) is secured by six cable ties (6) before
removing the cable ties.
6) Remove angle plug (10) from level controller
(1).
7) Disconnect wiring connector (11) from the
flat plug.
8) Mark the locations where air hose (7) is
secured by cable ties (12) before removing
the cable ties.
9) Mark the locations where compressor (3) is
secured by two cable ties (4) before
10)Pull out fitting (8) until it is removed from the
discharge port of compressor (3), and pull
out air hose (7).
WA1200-6 50-419
Cab
Installation
to get your hand caught and secure it
to prevent it from lowering by inserting
part.
2) Install support (9) to suspension lower part
(2).
3) Install compressor (3) to support (9).
4) Install cable ties (4) to the mounting locations
for cable ties (4) marked when removing
compressor (3).
a Loosely tighten cable ties (4) and position
them so that their heads are on the corner
above the compressor.
a Using pliers, secure the cable ties by
tightening in the direction indicated by an
arrow to a torque of 310 Nm {31.6 kgm}.
5) Install air hose (7) to fitting (8).
6) Install fitting (8) to the discharge port of
compressor (3).
7) Secure compressor (3) with cable ties (4).
a Install the compressor to the location
marked during removal.
8) Secure air hose (7) with cable ties (12).
9) Install wiring connector (11) for the flat plug.
10)Install angle plug (10) to level controller (1).
11)Secure compressor cable (5) with cable ties
(6).
a Secure the cable with no slack.
Install the rails.
14)Install the seat cushion. For details, see "2.
Seat and backrest cushions" in "I Removal
and installation of upper seat".
50-420 WA1200-6
Cab
7. Removal and installation of level controller
Removal 11)Mark the locations where pull wire (19) is

1) Remove the upper seat. For details, see "I secured by cable ties before removing them.
Upper seat". 12)Remove pull wires (3) and (19) from level
2) Remove the upper cover. For details, see "1. controller (1).
Removal and installation of upper cover". 13)Remove angle plugs (13) and (14) from level
3) Remove the boot. For details, see "3. controller (1).
Removal and installation of boot". a Mark the locations where angle plugs (13)
4) Raise the suspension to the uppermost level. and (14) are installed before removing
k Raise the suspension taking care not them.
to get your hand caught and secure it 14)Remove two nuts (4) from the stud bolt on
to prevent it from lowering by inserting level controller (1).
an appropriate spacer between the 15)Remove plate (7), belt (5), and edge
swing arm mechanism and the lower protector (6).
part. 16)Remove level controller (1) from suspension
5) Remove two circlips (17) from stud (18). upper part (8).
6) Remove stud (18) from lower part (15). 17)Remove TORX screw (9) and remove wire
a Carefully roll up belt (5) into the winder of attachment (2) from level controller (1).
level controller (1) while holding the belt a Remove the attachment by pushing two
tightly. catches (tabs) on the back of the attach-
7) Remove two buffers (16) from belt (5). ment.
8) Mark the locations where air hoses (10) and 18)Remove pull wire (3) from attachment (2).
(11) are secured by cable ties (12) before 19)Remove the entire level controller.
removing five cable ties (12).
9) Remove hoses (10) and (11) from the air
spring. (See "8. Installation and removal of
air hose".)
10)Mark the locations where angle plugs (13)
and (14) are secured by cable ties before
removing cable ties.
WA1200-6 50-421
Cab
Installation
to get your hand caught. Secure the
suspension to prevent it from lowering
by inserting an appropriate spacer be-
tween the swing arm mechanism and
the lower part.
2) Install the entire level controller.
3) Attach pull wire (3) to attachment (2).
4) Install wire attachment (2) to level controller
(1).
5) Install TORX screw (9) to level controller (1).
a Loosely tighten TORX screw (9).
6) Install level controller (1) to suspension
upper part (8).
7) Install edge protector (6), belt (5), and plate
(7).
8) Install two nuts (4) to the stud bolt on level
controller (1).
9) Install angle plugs (13) and (14) to level
controller (1).
a Install the angle plugs the locations
marked during removal.
10)Attach pull wires (3) and (19) to level
controller (1).
11)Secure pull wire (19) with cable ties.
12)Secure angle plugs (13) and (14) with cable
ties.
13)Install hoses (10) and (11) to the air spring.
14)Secure air hoses (10) and (11) with five cable
ties (12).
15)Install two buffers (16) to belt (5).
16)Install stud (18) to lower part (15).
17)Install two circlips (17) to stud (18).
20)Install the seat cushion. For details, see "2.
Seat and backrest cushions" in "I Disas-
sembly and assembly of upper seat".
50-422 WA1200-6
Cab
Adjustment 7) Make adjustment of exhaust valve (2)

1) Remove the upper seat. For details, see "I according to the following procedure. Adjust
Upper seat". the clearance between valve lever (6) and
2) Remove the upper cover. For details, see "1. cam disc (7) by turning exhaust valve adjust-
Removal and installation of upper cover". ment screw (10).
3) Remove the boot. For details, see "3. q Specified clearance: Adjust valve lever
Removal and installation of boot". (6) so that it slightly comes into contact
4) Raise the suspension to the uppermost level. with cam disc (7).
k Raise the suspension taking care not q Turning adjustment screw (10) to the left
to get your hand caught and secure it will move valve lever (6) closer to cam
to prevent it from lowering by inserting disc (7). This will increase pressure on
an appropriate spacer between the valve tappet (4), the exhaust timing being
swing arm mechanism and the lower accelerated.
part. q Turning adjustment screw (10) to the right
5) Loosen tapping screw (9) a half turn. will move valve lever (6) away from cam
6) Adjust micro switch (3) according to the disc (7). This will decrease pressure on
following procedure. Adjust the clearance valve tappet (4), the exhaust timing being
between cam switch (5) and cam disc (7) by decelerated.
turning micro switch adjustment screw (8). 8) After finishing adjustment, retighten tapping
q Specified clearance (A): 0.5 mm screw (9).
q Turning adjustment screw (8) to the left 9) Install the boot. For details, see "3. Removal
will move cam switch (5) closer to cam and installation of boot".
disc (7). 10)Install the upper cover. For details, see "1.
q Turning adjustment screw (8) to the right Removal and installation of upper cover".
will move cam switch (5) away from cam 11)Install the upper seat. For details, see "I
disc (7). Upper seat".
q With cam switch (5) held down by cam
disc (7), compressor (11) will be switched
on too early or will be switches on during
upward and downward movement of sus-
pension.
WA1200-6 50-423
Cab
8. Installation and removal of air hose
a Avoid reusing the hose. If it is reused, make a Be sure to push retainer ring (13) of the
sure it is free from damage. quick coupling all the way down when re-
Removal moving the hose.
1) Remove the upper seat. For details, see "I 9) Mark the locations where angled hose (8) is
Upper seat". secured by cable ties (6), (7), and (12) before
2) Remove the upper cover. For details, see "1. removing the cable ties.
Removal and installation of upper cover". 10)Remove angled hose (8).
3) Remove the boot. For details, see "3. 11)Mark the locations where air hoses (3) and
Removal and installation of boot". (4) are secured by cable ties (2) and (6)
4) Raise the suspension to the uppermost level. before removing the cable ties.
k Raise the suspension taking care not 12)Remove air hoses (3) and (4) from air spring
to get your hand caught and secure it (9).
to prevent it from lowering by inserting 13)Remove the controller with hoses (3) and (4)
an appropriate spacer between the being connected. (See "7. Removal and
swing arm mechanism and the lower installation of level controller".)
part. q Leave hoses (3) and (4) connected to the
5) Mark the locations where air hose (11) is level controller to prevent the loosening of
secured by cable ties (12) before removing the hose connection on the level control-
cable ties (12). ler side.
6) Remove air hose (11) from air spring (9).
a Be sure to push retainer ring (13) of the
quick coupling all the way down when re-
moving the hose.
7) Remove air hose (11) from compressor (5).
(See "6. Removal and installation of
compressor".)
8) Disconnect angled hose (8) from air spring
(9) and reservoir (10).
50-424 WA1200-6
Cab
Installation 6) Secure angled hose (8) with cable ties (6),

a Be sure to replace any damaged hose with a (7), and (12).
new one. It is possible to cut out damaged a Do not put cable ties on the angle.
part (approximately 12 mm) of the hose with 7) Install air hose (11) to compressor (5). (See
special tool (14) and reuse the hose only "6. Removal and installation of compressor".)
once. After the hose is cut out, move the blue 8) Install air hose (11) to air spring (9).
marking as long as it is cut. 9) Secure air hose (11) with cable ties (12).
1) Raise the suspension to the uppermost level. and installation of boot".
k Raise the suspension taking care not 11)Install the upper cover. For details, see "1.
to get your hand caught. Secure the Removal and installation of upper cover".
suspension to prevent it from lowering 12)Install the upper seat. For details, see "I
by inserting an appropriate spacer be- Upper seat".
tween the swing arm mechanism and
the lower part. Air leakage test
2) Install the controller with hoses (3) and (4) a After disassembling and assembling the air
being connected. hose, be sure to perform the air leakage test.
a If hoses (3) and (4) are damaged, replace q Place a weight of 60 kg on the hose and
with new ones. Cut an extra length of the leave it alone for 24 hours.
hose. q There should be no sinkage of more than
3) Install air hoses (3) and (4) to air spring (9). 15 mm.
4) Secure air hoses (3) and (4) with cable ties a After connecting the air hose, check that it is
(2) and (6). appropriately locked.
5) Install angled hose (8) to air spring and reser-
voir.
a First attach the angled hose to the air
spring to prevent kinking.
a When connecting angled hose (8) to air
spring (9) and reservoir (10), be sure to
insert the hose as far as the mark.
WA1200-6 50-425
Cab
9. Removal and installation of height adjustment 10)Remove entire holder (4) of pull wire.
wire and lever 11)Remove lever(5). (If replacement is required)
a Lever (5) and holder (4) are held by two
tabs (indicated by arrows) on the back
and require careful disassembling.
a To disassemble the lever, open up the
space between lever (5) and holder (4)
using a screwdriver and remove the tabs.
a Remove handle (5) from holder (4).
Installation
1) Install lever (5) to holder (4). (If the lever was
removed from the holder)
a Replace the lever if deformed.
2) Attach pull wires (1) and (6) to holder (4).
a If the wire is replaced with a new one, ad-
just it to the same length as the one re-
moved.
3) Install holder (4) to suspension upper part (2)
and secure it with mounting screw (7).
4) Attach pull wire (6) to the level controller.
(See "7. Removal and installation of level
controller".)
5) Attach pull wire (1) to the level controller
holder. (See "7. Removal and installation of
level controller".)
6) Secure pull wire (6) with two cable ties (8).
a Use care not to kink the wire when secur-
ing it.
7) Secure pull wire (1) with two cable ties (3).
a Use care not to kink the wire when secur-
Removal ing it.
1) Remove the upper seat. For details, see "I 8) Install the boot. For details, see "3. Removal
Upper seat". and installation of boot".
2) Remove the upper cover. For details, see "1. 9) Install the upper cover. For details, see "1.
Removal and installation of upper cover". Removal and installation of upper cover".
3) Remove the boot. For details, see "3. 10)Install the upper seat. For details, see "I
Removal and installation of boot". Upper seat".
4) Mark the locations where pull wire (1) is
5) Mark the locations where pull wire (6) is
6) Remove pull wire (1) from the level controller
holder. (See "7. Removal and installation of
level controller".)
a Loosen the tension of pull wire (1) by rais-
ing height adjustment lever (5).
7) Remove pull wire (6) from the level controller.
controller".)
a Loosen the tension of pull wire (6) by rais-
ing height adjustment lever (5).
8) Remove screw (7).
9) Remove pull wires (1) and (6) from holder (4)
and remove the wires from suspension upper
part (2).
50-426 WA1200-6
Cab
Testing and adjusting a The suspension will not rise when this val-
a Perform the following measurements and ad- ue is over 3.5 mm.
justments for height adjustment before in-
stalling the top cover. (Adjustment)
a To perform measurements and assembling 1) Adjusting pull wire (3)
during the course of disassembly and as- 1] The clearance between wire lever (10)
sembly, omit steps 1) and 2) in Measuring. and wire holder (9) can be adjusted by
loosening counter nut (6) and turning lock
(Measuring) nut (5).
1) Remove the upper seat. For details, see "I q Turn lock nut (5) inward to increase
Upper seat". the length of wire.
2) Remove the upper cover. For details, see "1. q Turn lock nut (5) outward to decrease
Removal and installation of upper cover". the length of wire.
3) Move height adjustment lever (2) up and Specified value: Clearance (A) is 1 to 3.5
down several times to check that: mm (with the height adjustment lever
q Pull wires (1) and (3) move smoothly. raised)
q Pull wire (10), valve lever (14), and tappet 2] After the adjustment, secure lock nut (5)
(13) of the exhaust valve move smoothly. with counter nut (6). Take care not to kink
4) Check the tension of spring (11) for the level wire (3).
control and valve with height adjustment 3] Check that the specified value is satisfied
lever (2) placed in the middle position. by moving the height adjustment lever up
q Spring (11) secures the height adjust- and down several times.
ment lever in the middle position.
q Spring (11) substantially pulls pull wires
(1) and (3) and holds wire lever (10) in the
middle position.
5) Measure the clearance between wire lever
(10) and wire holder (9).
Specified value: (A) = 1 to 3.5 mm with the
height adjustment lever fully raised
WA1200-6 50-427
Cab
2) Adjusting pull wire (1)

1] Pull wire (1) of the level controller can be
adjusted by loosening counter nut (7) and
turning lock nut (8).
q Turn lock nut (8) inward to increase
the length of wire.
q Turn lock nut (8) outward to decrease
the length of wire.
q Specified value: The pull wire must be
slightly taut with no kinks.
2] After the adjustment, secure lock nut (8)
with counter nut (7). Take care not to kink
wire (1).
3] Check that the level controller operates
by moving the height adjustment lever up
and down several times.
a If testing and service is performed indepen-

dently without performing disassembly and
assembly, perform steps 10) to 12) and then
install the seat cushion.
50-428 WA1200-6
Cab
10. Removal and installation of air spring
1) Remove the upper seat. For details, see "I 1) Raise the suspension to the uppermost level.
Upper seat". k Raise the suspension taking care not
2) Remove the upper cover. For details, see "1. to get your hand caught. Secure the
Removal and installation of upper cover". suspension to prevent it from lowering
3) Remove the boot. For details, see "3. by inserting an appropriate spacer be-
Removal and installation of boot". tween the swing arm mechanism and
4) Remove two hoses from air spring (6). (See the lower part.
"8. Installation and removal of air hose".) 2) Turn the entire suspension upside down.
5) Remove countersunk screw (3) and washer 3) Compress air spring (6) and set it between
(4) from the air spring. swing arm (5) and lower part (2).
6) Raise the suspension to the uppermost level. a Move the air spring until protruding por-
k Raise the suspension taking care not tion (6) on the bottom of the air spring fits
to get your hand caught. Secure the into the hole in the suspension lower part.
suspension to prevent it from lowering 4) Install countersunk screw (7) to the air spring.
by inserting an appropriate spacer be- 3 Mounting screw:
tween the swing arm mechanism and 6 Nm {0.61 kgm}
the lower part. 5) Turn the entire suspension back to its original
7) Turn the entire suspension upside down. position.
8) Remove countersunk screw (7) from the air 6) Fit washer (4) to countersunk screw (3) and
spring. install it to the air spring.
9) Compress air spring (6) and remove swing 3 Mounting screw:
arm (5) and lower part (2). 6 Nm {0.61 kgm}
7) Install two air hoses to air spring (6). (See "8.
Installation and removal of air hose".)
WA1200-6 50-429
Cab

Upper seat".
50-430 WA1200-6
Cab
11. Removal and installation of air reservoir
4) Raise the suspension to the uppermost level. the lower part.
k Raise the suspension taking care not 2) Install clamp (5), if removed, to bracket (6).
to get your hand caught. Secure the a Replace clamp (5) if necessary.
suspension to prevent it from lowering 3) Install air reservoir (3) to bracket (2) and
by inserting an appropriate spacer be- clamp (5).
tween the swing arm mechanism and 4) Install angled hose (4) to air reservoir (3).
the lower part. (See "8. Installation and removal of air
5) Remove angled hose (4) from air reservoir hose".)
(3). (See "8. Installation and removal of air 5) Install the boot. For details, see "3. Removal
hose".) and installation of boot".
6) Remove air reservoir (3) from bracket (2) and 6) Install the upper cover. For details, see "1.
clamp (5). Removal and installation of upper cover".
7) Remove clamp (5) from bracket (6). (If 7) Install the upper seat. For details, see "I
replacement is required) Upper seat".
a Put a screwdriver into the hole (indicated
by an arrow) in bracket (6) to remove the
clamp catch (indicated by an arrow) and
remove clamp from the bracket.
WA1200-6 50-431
Cab
12. Removal and installation of harness
4) Raise the suspension to the uppermost level. the lower part.
k Raise the suspension taking care not 2) Install angle plug (6) to level controller (1).
to get your hand caught. Secure the 3) Install flat plug, connector plug and harness
suspension to prevent it from lowering (2) of compressor cable (4) to vehicle power
by inserting an appropriate spacer be- cable (3). (See "8. Installation and removal of
tween the swing arm mechanism and air hose".)
the lower part. 4) Secure connector cable (2) and power cable
5) Mark the location where power cable (3) is (3) with cable ties (5).
secured by cable tie (8) before removing the a Run harnesses (2) and (3) taking care not
cable tie. to allow them to get caught in other parts
6) Mark the location where connector cable (2) when securing them with cable ties.
and vehicle power cable (3) are secured by 5) Secure power cable (3) with cable ties (8).
cable ties (5) before removing the cable ties. 6) Install the boot. For details, see "3. Removal
7) Disconnect flat plug, connector plug and and installation of boot".
harness (2) of compressor cable (4) from 7) Install the upper cover. For details, see "1.
vehicle power cable (3). (See "8. Installation Removal and installation of upper cover".
and removal of air hose".) 8) Install the upper seat. For details, see "I
8) Remove angle plug (6) from the level Upper seat".
controller.
50-432 WA1200-6
Cab
13. Disassembly and assembly of suspension upper

part
Disassembly 8) Raise the suspension to the uppermost level.

1) Remove the upper seat. For details, see "I k Raise the suspension taking care not
Upper seat". to get your hand caught. Secure the
2) Remove the upper cover. For details, see "1. suspension to prevent it from lowering
Removal and installation of upper cover". by inserting an appropriate spacer be-
3) Remove the boot. For details, see "3. tween swing arm mechanism (7) and
Removal and installation of boot". the lower part.
4) Remove the damper adjustment lever and 9) Hollow the head of two rivets (10) to remove
pull wire from suspension upper part (1). them, and remove stopper (9).
(See "4. Removal and installation of damper 10)Push suspension upper part (1) forward to
adjustment wire and lever".) move roller (8) to the opening (indicated by
a It is not necessary to remove the wire an arrow) in guide rail (2).
from the damper. 11)Raise upper part (1) and remove it from front
5) Remove the damper from suspension upper roller (8) and rear roller (6) in swing arm
part (1). (See "5. Removal and installation of mechanism (7).
damper".)
6) Remove the level controller from upper part
(1). (See "7. Removal and installation of level
controller".)
a It is not necessary to remove the air hose
from the air spring.
7) Remove the height adjustment lever and
wire. (See "9. Removal and installation of
height adjustment wire and lever".)
WA1200-6 50-433
Cab
Assembly
to get your hand caught. Secure the
suspension to prevent it from lowering
by inserting an appropriate spacer be-
tween swing arm mechanism (7) and
the lower part.
2) Push suspension upper part (1) forward to
move roller (8) to the opening (indicated by
an arrow) in guide rail (2).
3) Raise upper part (1) and install it to rear roller
(8) and front roller (6) in swing arm mecha-
nism (7).
the sides (F) of the guide rail.
4) Install stopper (9) and secure it with rivet
(10).
5) Install the height adjustment lever and wire.
(See "9. Removal and installation of height
adjustment wire and lever".)
6) Install the level controller to upper part (1).
controller".)
7) Install the damper to suspension upper part
(1). (See "5. Removal and installation of
damper".)
8) Install the damper adjustment lever and pull
wire to suspension upper part (1). (See "4.
Removal and installation of damper adjust-
ment wire and lever".)
Upper seat".
50-434 WA1200-6
Cab
14. Disassembly and assembly of suspension lower

part
Disassembly 11)Raise upper part (1) and swing arm (3) to

1) Remove the upper seat. For details, see "I remove roller (2) from guide rail (8).
Upper seat".
2) Remove the upper cover. For details, see "1.
3) Remove the boot. For details, see "3.
Removal and installation of boot".
4) Remove the compressor. For details, see "6.
Removal and installation of compressor".
a It is not necessary to remove the cables
and hoses.
a Secure the swing arm with adhesive tape
to protect the compressor from impact.
5) Remove the belt from lower part (7). (See "7.
Removal and installation of level controller".)
6) Remove the countersunk screw from the air
spring. (See "10. Removal and installation of
air spring".)
7) Remove the cable ties from the vehicle
power cable in lower part (7). (See "12.
Removal and installation of harness".)
8) Remove two each nuts (11), washers (10),
and countersunk screws (9).
9) Remove two bolts (5) and two U-profiles (6)
from guide rail (8).
10)Push suspension upper part (1) backward
together with swing arm (3) until bearing (4)
is removed from the opening (indicated by an
arrow) in guide rail (8).
WA1200-6 50-435
Cab
Assembly
1) Raise upper part (1) and swing arm (3) to
install roller (2) to guide rail (8).
the sides (F) of guide rail (8) of roller (2).
2) Install bolts (5) and U-profiles (6) to guide rail
(8).
3) Install countersunk screws (9), washers (10)
and nuts (11).
4) Secure the vehicle power cable in lower part
(7) with cable ties. (See "12. Removal and
installation of harness".)
5) Install the countersunk screw to the air
spring. (See "10. Removal and installation of
air spring".)
6) Install the belt to lower part (7). (See "7.
Removal and installation of level controller".)
7) Install the compressor. For details, see "6.
Removal and installation of compressor".
Upper seat".
50-436 WA1200-6
Cab
15. Disassembly and assembly of swing arm
Disassembly 12)Remove the harness. (See "12. Removal and

1) Remove the upper seat. For details, see "I installation of harness".)
Upper seat". 13)Remove the suspension upper part from the
2) Remove the upper cover. For details, see "1. swing arm. (See "13. Disassembly and
Removal and installation of upper cover". assembly of suspension upper part".)
3) Remove the boot. For details, see "3. 14)Remove the suspension lower part from the
Removal and installation of boot". swing arm. (See "14. Disassembly and
4) Remove the pull wire from the damper. (See assembly of suspension lower part".)
"4. Removal and installation of damper 15)Remove four rollers (5), two rollers (6), two
adjustment wire and lever".) bearings (9) and four felt rings (4) from swing
5) Remove the damper from the swing arm. arm (1).
(See "5. Removal and installation of 16)Remove tube (8) from bearing (9).
damper".) 17)Remove buffer (7) from swing arm (1).
6) Remove the compressor. (See "6. Removal 18)Remove edge protector (2) from swing arm
and installation of compressor".) (1).
7) Remove the belt from the suspension lower
part. (See "7. Removal and installation of
level controller".)
8) Remove the cable ties secured to the air
hose leading to the level controller, and
remove the hose from the air spring. (See "8.
Installation and removal of air hose".)
9) Remove the pull wire leading to the level
control and valve. (See "9. Removal and
installation of height adjustment wire and
lever".)
10)Remove the air spring. (See "10. Removal
and installation of air spring".)
11)Remove the air reservoir. (See "11. Removal
and installation of air reservoir".)
WA1200-6 50-437
Cab
Assembly
1) Measure the maximum clearance (A) and (B)
between the guide rail of lower part (11) and
upper part (10) and roller (5) across the entire
movement range of the roller.
2) If necessary, insert washer (3) between roller
(5) or (6) and swing arm shaft to compensate
for the clearance.
a Washers (0.2 and 0.5 mm) are included in
the consumable parts kit.
3) Install edge protector (2) to swing arm (1).
4) Install buffer (7) to swing arm (1).
5) Install tube (8) to bearing (9).
6) Install four rollers (5), two rollers (6), two
bearings (9) and four felt rings (4) to swing
arm (1).
7) Install the suspension lower part to the swing
arm. (See "14. Disassembly and assembly of
suspension lower part".)
8) Install the suspension upper part to the swing
arm. (See "13. Disassembly and assembly of
suspension upper part".)
9) Install the harness. (See "12. Removal and
installation of harness".)
10)Install the air reservoir. (See "11. Removal
and installation of air reservoir".)
11)Install the air spring. (See "10. Removal and
installation of air spring".)
12)Attach the pull wire leading to the level
control and valve. (See "9. Removal and
installation of height adjustment wire and
lever".)
13)Install the air hose leading to the level
controller to the air spring and secure it with
cable ties. (See "8. Installation and removal
of air hose".)
14)Install the belt to the suspension lower part.
controller".)
15)Install the compressor. (See "6. Removal and
installation of compressor".)
16)Install the damper to the swing arm. (See "5.
Removal and installation of damper".)
17)Attach the pull wire to the damper. (See "4.
Removal and installation of damper adjust-
ment wire and lever".)
Upper seat".
50-438 WA1200-6
Electrical system
Removal and installation of DT connector pin

Removal and installation of DT connector pin 50-439

1. Using nippers, tweezers, or pull-out tool, pull out 1. Hold wire (4) 30 mm away from the rear of the
wedge (1) from the DT connector. (The following caulked portion of the contact.
photo shows the male side.)
2. Insert wire (4) in the grommet side of the

2. While disconnecting contact fixing claw (2) in the connector.
connector from the contact by using flat-head a Insert the contact for selecting wire (4)
screwdriver, tweezers, or pull-out tool, pull out straight into the grommet insertion hole until
wires, and release the fixing claw. it clicks.
a Insert the wire to the back until it clicks
(sound is heard when the contact passes
through the fixing claw), and until you feel
that the contact presses against the back
wall.
a Slightly pull out the wire in the pull-out direc-
tion, and check that the contact at the end of
the wire is not removed.
3. While holding rubber shield (grommet) (3), pull

out wire (4).
WA1200-6 50-439
Electrical system
Removal and installation of DT connector pin
3. After inserting all wires, install wedge (1).

a For 3-pole pin connectors, install the wedge
into both male and female connectors with
the arrow on the wedge facing the joint of the
connector housing. (The following photo
shows the male coonector.)
50-440 WA1200-6
Electrical system
Removal and installation of HD connector pin
Removal and installation of HD connector pin 50-4 1
Removal 50-4 1 Installation 50-4 1

1. Select the appropriate tool for the wire size from 1. Hold wire (2) 30 mm away from the rear of the
the "special tools list", and install it to the wire of caulked portion of the contact.
the pin to be removed.
2. Insert the wire in the grommet of the connector.

2. Insert tool X1 into the clearance of wire a Insert the contact straight into the grommet
connector rubber shield (1), and press it against insertion hole until it clicks.
the contact. a Insert the wire to the back until it clicks
a Use a larger tool than the wire. (sound is heard when the contact passes
a Take care not to damage the contact. through the fixing claw), and until you feel
3. Pull out wire (2) together with tool X1. that the contact presses against the back
wall.
a Slightly pull out the wire in the pull-out direc-
tion, and check that the contact at the end of
the wire is not removed.
WA1200-6 50-441
Electrical system
Repairing HD connector pin harness
Repairing HD connector pin harness 50-4 2
1. Remove the wire cover. 5. Insert contact (5) into caulking tool X2.
a For removal dimensions, see the table be- a Adjust adjustment screw (4) so that the upper
low, side of contact (5) is level with the top edge
Wire size Cover removal dimen- "a" of the tool hole. Then, fasten lock nut (3).
JIS SAE sions (mm)
0.5 2–24AWG 3.96–5.54
0.5–0.85 16–20AWG 6.35–7.92
1.25–2.0 14–16AWG 6.35–7.92
2.0–3.0 12–14AWG 5.64–7.21
7.0 8–10AWG 10.9–12.5
15.0 6AWG 10.9–12.5
2. Remove pin (1) of caulking tool X2.
3. Lift and turn knob (2) to select the size position

appropriate for the wire dimension (the AWG
size shown above is indicated on tool X2).
6. Insert wire (6) in the contact (5).
4. Loosen lock nut (3), and turn adjustment screw

(4).
7. Grip the handle to caulk the contact.

a Gripping the handle up to its stroke end
opens the handle.
50-442 WA1200-6
Electrical system
Removal and installation of controller assembly
Removal and installation of controller assembly 50-4 3
Removal 50-4 3 5. Disconnect wiring harness connectors L5, L6,

k Before performing removal, be sure to imple- and L7. Remove the mounting bolts and remove
ment "2. Preparatory work" and "3. Precau- BBC controller assembly (6).
q ATC controller assembly

q VHMS controller assembly
q BBC controller assembly
1. Remove covers (1) and (2).
q Engine controller assembly
6. Disconnect wiring harness connectors (7), (8),

and (9). Remove the mounting bolts and remove
engine controller assembly (10).
Installation 50-4 3
moval.
3. Disconnect wiring harness connectors V1, V2A,
V2B, V3A, V3B, V4A, and V4B. Remove the
mounting bolts and remove VHMS controller
assembly (4).
4. Disconnect wiring harness connectors L02, L03,

and L04. Remove the mounting bolts and
remove ATC controller assembly (5).
WA1200-6 50-443
Electrical system
Removal and installation of controller assembly
50-444 WA1200-6
SEN0547529-00 60-1
WA1200-6
WHEEL LOADER
Shop Manual 6-01
WA1200-6

WA1200-6 60001 and up
60 Maintenance standard 60-1
WA1200-6 60-1
Contents
Contents 60-2
60 Maintenance standard
Engine mount....................................................................................................................... 60- 3
Cooling system .................................................................................................................... 60- 4
Damper ................................................................................................................................ 60- 7
Power train.............................................................................................................................. 60- 8
Transmission mount............................................................................................................. 60- 8
Main relief valve, torque converter relief valve..................................................................... 60- 14
ECMV................................................................................................................................... 60- 17
Transmission........................................................................................................................ 60- 18
Lubrication relief valve ......................................................................................................... 60- 23
Transfer................................................................................................................................ 60- 24
Torque converter pump, transmission pump, brake cooling pump, brake pump ................. 60- 26
Drive shaft............................................................................................................................ 60- 28
Center support ..................................................................................................................... 60- 30
Differential............................................................................................................................ 60- 32
Final drive ............................................................................................................................ 60- 36
Steering system ...................................................................................................................... 60- 38
Steering pump...................................................................................................................... 60- 38
Switch pump ........................................................................................................................ 60- 39
Diverter valve ....................................................................................................................... 60- 43
Steering cylinder mount ....................................................................................................... 60- 44
Steering cylinder .................................................................................................................. 60- 45
Emergency steering pump ................................................................................................... 60- 47
Brake system .......................................................................................................................... 60- 48
Brake valve .......................................................................................................................... 60- 48
Slack adjuster ...................................................................................................................... 60- 50
Brake.................................................................................................................................... 60- 51
Parking brake....................................................................................................................... 60- 52
axle mount ........................................................................................................................... 60- 54
Center hinge pin................................................................................................................... 60- 56
No.1 work equipment pump ................................................................................................. 60- 59
No.2 work equipment pump ................................................................................................. 60- 62
PPC relief valve ................................................................................................................... 60- 65
Pump control relief valve...................................................................................................... 60- 66
Work equipment control valve.............................................................................................. 60- 67
Work equipment...................................................................................................................... 60- 69
Bucket positioner, remote positioner.................................................................................... 60- 74
Work equipment cylinder ..................................................................................................... 60- 75
60-2 WA1200-6
Engine mount

Engine mount 60-3
WA1200-6 60-3
Cooling system
Cooling system 60-4
No. Item Unit Criteria Remarks

Average wind Engine speed:
– m/s 15 or above
speed 1,900 rpm
– Load factor % 91
– Ambient temperature (conversion) °C 50

Radiator inlet/outlet water tempera- See Inspection and Adjustment - "Radiator
1 °C 6.3 to 8
ture difference Performance Check".
See Inspection and Adjustment - "Hydraulic
Hydraulic oil cooler inlet/outlet oil
2 °C 11 to 13 Oil Cooler Performance Check (Check by
temperature difference
Temperature Difference)".
Torque converter oil cooler
See Inspection and Adjustment - "Torque
3 inlet/outlet oil temperature differ- °C 11 to 13
Converter Oil Cooler Performance Check".
ence
– Hydraulic tank oil temperature °C 104.5
60-4 WA1200-6
Cooling fan motor
Cooling fan motor 60-5

Model: LMF40 60-5
WA1200-6 60-5
Cooling fan motor
Unit: mm
No. Item Criteria Remedy

Standard dimension Repair limit
Free length x Load at Load at
Installed Free
Outside diam- installed installed
1 Center spring length length
eter length length
If damaged or
931 N 745 N
33.5 x 31 25.5 32.7 deformed, replace
{95 kg} {76 kg}
spring
3.43 N 2.74 N
2 Check valve spring 13.0 x 6.5 7 12.7
{0.35 kg} {0.28 kg}
68 N 54.4 N
3 Spring return spring 12.2 x 7.9 10 11.9
{6.9 kg} {5.52 kg}
60-6 WA1200-6
Damper
Damper 60-7
Unit: mm

Standard Tolerance Standard Allowable
Clearance between bearing and dimension Shaft Hole clearance clearance
1
shaft +0.018 0 -0.038 to
120 0
+0.003 -0.020 -0.003 Replace
Clearance between bearing and 0 -0.008 -0.037 to
2 215 0.025
housing -0.030 -0.037 0.022
Clearance between spacer and +0.018 -0.020 -0.060 to
3 120 0
shaft +0.003 -0.042 -0.023
Standard dimension Tolerance Repair limit
Wear of oil seal contact surface of
4 0
shaft 150 -0.160
-0.100
Repair chrome plat-
Wear of spacer oil seal contacting 0
5 140 -0.160 ing or replace
surface -0.100
Wear of spacer O-ring contacting 0
6 140 -0.160
surface -0.100
7 Backlash of spline 0.091 to 0.261 Replace
WA1200-6 60-7
Power train
Transmission mount
Power train 60-8

Transmission mount 60-8
60-8 WA1200-6
Power train
Transmission mount
Unit: mm

Clearance between torque con- dimension Shaft Hole clearance clearance
1
verter case and trunnion -0.125 +0.089 0.125 to
320
-0.214 0 0.303 Replace
Clearance between bracket and 0 +0.035 0 to
2 90
bushing -0.035 0 0.070
Clearance between bushing and +0.123 +0.089 -0.123 to
3 125
bracket +0.083 0 -0.006
Center of top and bottom center pins and transmission
output shaft
4 Standard shim thickness for mount 1.5 mm –
Parallelism of coupling contacting surface must be 0.15
mm or less.
WA1200-6 60-9
Power train
Torque converter

(Input transfer, PTO, modulation clutch, torque converter)
Input transfer, PTO 60-10
60-10 WA1200-6
Power train
Torque converter
Unit: mm

Outside diameter of coupling oil Standard dimension Tolerance Repair limit Repair by hard
1 seal 0 chrome plating or
f110 109.8
contacting surface -0.087 replace
Backlash between drive gear and
2 0.15 to 0.33
PTO gear
Backlash between driver gear and
3 0.15 to 0.33
idler gear
Backlash between idler gear and
4 0.15 to 0.32
driven gear
Interference of drive gear and bear- dimension Shaft Hole clearance clearance
5
ing +0.045 0 0.023 to 0.023 to
f100
+0.023 -0.20 0.065 0.065 Replace
Interference of drive gear bearing 0 -0.012 -0.023 to -0.023 to
6 f180
and cage -0.025 -0.052 0.052 0.052
Interference of PTO gear and bear- +0.045 0 0.023 to 0.023 to
7 f100
ing +0.023 -0.20 0.065 0.065
Interference of PTO gear bearing 0 -0.012 -0.023 to -0.023 to
8 f180
and cage -0.025 -0.052 0.052 0.052
Interference of idler gear and bear- +0.045 0 0.023 to 0.023 to
9 f100
ing +0.023 -0.20 0.065 0.065
Interference of idler gear bearing 0 -0.012 -0.023 to -0.023 to
10 f180
and cage -0.025 -0.052 0.052 0.052
WA1200-6 60-11
Power train
Torque converter
Modulation clutch 60-12
Unit: mm

Bore of bush seal ring
1 +0.035
contacting surface f85 84.8
0
-0.01
Wear of seal ring of Width 3 2.7
-0.03
2 modulation clutch output
shaft Thickness 3.5 ±0.1 3.35
Replace
Total thickness of assembly of 19
3 disks and 18 plates for modulation 107.6 ±0.41 96.2
clutch
Modulation clutch
4 3.2 ±0.08 2.6
disk thickness
Modulation clutch
5 2.6 ±0.05 2.34
plate thickness
60-12 WA1200-6
Power train
Torque converter
Unit: mm

Bore of retainer seal ring
1 +0.040 Repair by hard
contacting surface f180 180.5
0 chrome plating or
Bore of sleeve seal ring +0.035 replace
2 f85 85.1
contacting surface 0
0
Width 5.95 5.45
Wear of retainer seal -0.1
3
ring
Thickness 6.3 ±0.1 5.67
Replace
4 Plate thickness 9 ±0.1 8.5
5 Retainer thickness 32 ±0.1 31.5
WA1200-6 60-13
Power train
Main relief valve, torque converter relief valve
Main relief valve, torque converter relief valve 60-14
60-14 WA1200-6
Power train
Main relief valve, torque converter relief valve
Unit: mm

Clearance between main relief dimension Shaft Hole clearance clearance
1
valve spool and valve body -0.035 +0.016 0.035 to
f50 0.081
-0.045 0 0.061
Clearance between main relief -0.020 +0.025 0.020 to
2 f32 0.075
valve spool and piston -0.030 0 0.055
Clearance between torque con-
-0.035 +0.016 0.035 to
3 verter relief valve spool and valve f40 0.081
-0.045 0 0.061
body
Clearance between torque con- -0.020 +0.021 0.020 to
4 f28 0.071
verter relief valve spool and piston -0.030 0 0.051
Standard dimension Repair limit Replace
Installation Installation Installation
Main relief valve Free length Free length
5 length load load
valve spring (outer)
958 N 910.1 N
143.2 105 138.9
{97.8 kg} {92.9 kg}
Main relief valve 1,102 N 1,046.9 N
6 130.6 105 126.7
valve spring (inner) {112.4 kg} {106.8 kg}
Main relief valve 30.0 N 28.5 N
7 53 33 51.4
piston spring {3.06 kg} {2.91 kg}
Torque converter relief valve 677.6 N 644.3 N
8 116.92 84.8 113.4
valve spring {69.1 kg} {65.7 kg}
Torque converter relief valve 30.0 N 28.5 N
9 53 33 51.4
WA1200-6 60-15
Power train
Torque converter regulator valve 60-16
Unit: mm

dimension Shaft Hole clearance clearance
1 verter regulator valve spool and
valve body -0.035 +0.016 0.035 to
f40 0.081
-0.045 0 0.061
-0.020 +0.021 0.020 to
2 verter regulator valve spool and pis- f22 0.071
-0.030 0 0.051
ton
Torque converter regulator valve Free length Free length
3 length load load
valve spring (outer)
165.2 N 156.9 N
160.4 93 155.6
{16.85 kg} {16.01 kg}
Torque converter regulator valve 72.3 N 68.7 N
4 160 93 155.2
valve spring (inner) {7.37 kg} {7.0 kg}
Torque converter regulator valve 27.9 N 26.5 N
5 38.2 21 37.1
60-16 WA1200-6
Power train
ECMV
ECMV 60-17
(For modulation clutch) 60-17
Unit: mm

Clearance between flow rate
1 detection valve spool and valve
body -0.035 +0.013 0.035 to
f19 0.064
-0.045 0 0.058
Clearance between pressure -0.035 +0.011 0.035 to
2 f14 0.062
control valve spool and valve body -0.045 0 0.056
3 f5.7 0.063
control valve spool and piston body -0.045 0 0.057
Free length Free length
4 Spring for fill switch length load load
41.7 N 37.6 N
15 13 14.7
{4.25 kg} {3.83 kg}
Flow rate detection valve 4.9 N 4.4 N
5 33.5 29.5 32.8
return spring {0.5 kg} {0.45 kg}
Pressure control valve 10.6 N 9.5 N
6 16.2 11.7 15.9
WA1200-6 60-17
Power train
Transmission
Transmission 60-18
60-18 WA1200-6
Power train
Transmission
Unit: mm

Standard dimension Allowable clearance
1 No.1 clutch spring (x 6) length load load
379.5N 322.6N
133 94 125.02
{38.7kg} {32.9kg}
536.4N 456.0N
2 No.2 clutch spring (x 6) 168 106 157.92
{54.7kg} {46.5kg}
357.9N 304.0N
3 No.3 clutch spring (x 6) 68.8 55 64.67
{36.5kg} {31.0kg}
42.7N 358.9N
4 No.4 clutch spring (x 6) 56.9 43 53.49
{43.0kg} {36.6kg}
1697N 1443N
5 No.5 clutch spring (x 3) 9.5 8.8 8.93
{173.0kg} {147.1kg}
6
disks and 7 plates for No.1 clutch 83.8 ±0.39 79.5
7 95.0 ±0.41 90.2
disks and 8 plates for No.2 clutch
8 50.2 ±0.30 47.5
9 39.0 ±0.26 36.9
10 77.6 ±0.41 72.8
11 Thickness of No.1 to 4 clutch disks 5.4 ±0.1 4.87
12 Thickness of No.5 clutch disk 4.8 ±0.1 4.27

Replace
13 Thickness of No.1 to 4 clutch plates 5.8 ±0.1 5.22
14 Thickness of No.5 clutch plate 4.3 ±0.1 3.87

-0.01
Width 3 2.7
Wear of transmission -0.03
15
input shaft sealing
Thickness 3.5 ±0.1 3.35
-0.01
Width 4 3.6
Wear of transmission -0.03
16
output shaft sealing
Thickness 4.6 ±0.12 4.45
-0.01
Width 6 5.5
Wear of No.5 clutch -0.03
17
sealing
Thickness 6.8 ±0.15 6.65
Backlash between No.1, 2, 3 sun
18 0.16 to 0.40
gears and planet pinion
Backlash between No.1 planet pin-
19 0.18 to 0.43
ion and ring gear internal tooth
Backlash between No.2 and 3
20 planet pinions and ring gear inter- 0.19 to 0.47
nal tooth
Backlash between No.4 sun gear
21 0.17 to 0.39
and planet pinion
Backlash between No.4 planet pin-
22 0.18 to 0.44
ion and ring gear internal tooth
23 Side clearance of planet pinion 0.35 to 0.80 (both sides)
WA1200-6 60-19
Power train
Transmission control valve 60-20

ECMV (for transmission) 60-20
Unit: mm

Clearance between flow rate
1 detection valve spool and valve
body -0.035 +0.013 0.035 to
f19 0.064
-0.045 0 0.058
2 f14 0.062
control valve spool and valve body -0.045 0 0.056
3 f5.7 0.063
control valve spool and piston -0.045 0 0.057
4 Spring for fill switch length load load
41.7 N 37.6 N
15 13 14.7
{4.25 kg} {3.83 kg}
Flow rate detection valve 4.9 N 4.4 N
5 33.5 29.5 32.8
Pressure control valve 10.6 N 9.5 N
6 16.2 11.7 15.9
60-20 WA1200-6
Power train
Clutch bypass fill valve 60-21

(For forward clutch and 1st clutch)
Unit: mm

Clearance between bypass fill dimension Shaft Hole clearance clearance
1
f14 0.076
-0.045 0 0.056
Installation Installation Installation Replace
Bypass fill valve Free length Free length
2 length load load
return spring (outer)
63.7 N 60.8 N
33.4 17.3 32.4
{6.5 kg} {6.2 kg}
Bypass fill valve 33.3 N 31.4 N
3 38.2 17.3 37.1
return spring (inner) {3.4 kg} {3.2 kg}
WA1200-6 60-21
Power train
Clutch bypass fill valve, bypass drain valve 60-2

(for reverse clutch)
Unit: mm

Clearance between bypass fill dimension Shaft Hole clearance clearance
1
f14 0.076
-0.045 0 0.056
Clearance between bypass drain -0.035 +0.011 0.035 to
2 f14 0.076
valve spool and valve body -0.045 0 0.056
Bypass fill valve Free length Free length
3 length load load
return spring (outer)
63.7 N 60.8 N
33.4 17.3 32.4
{6.5 kg} {6.2 kg}
Bypass fill valve 33.3 N 31.4 N
4 38.2 17.3 37.1
return spring (inner) {3.4 kg} {3.2 kg}
Bypass drain valve 63.7 N 60.8 N
5 33.4 17.3 32.4
60-22 WA1200-6
Power train
Lubrication relief valve
Lubrication relief valve 60-23
Unit: mm

Clearance between lubrication dimension Shaft Hole clearance clearance
1
relief valve spool and valve body -0.035 +0.013 0.035 to
f22 0.078
-0.045 0 0.058
Lubrication relief valve Free length Free length
2 length load load
valve spring
91.9 N 87.3 N
68.5 37 66.4
{9.37 kg} {8.9 kg}
WA1200-6 60-23
Power train
Transfer
Transfer 60-24
60-24 WA1200-6
Power train
Transfer
Unit: mm

Outside diameter of front coupling
1 +0.052
oil seal contacting surface f140 139.8
+0.027
Outside diameter of rear coupling +0.052
2 f140 139.8
oil seal contacting surface +0.027
Backlash between input gear and
3 0.25 to 0.65
idler gear
Backlash between idler gear and
4 0.25 to 0.65
output gear
Interference of input gear and bear- dimension Shaft Hole interference interference
5
ing +0.078 0 0.060 to 0.060 to
f140
+0.060 -0.025 0.103 0.103
Interference of input gear bearing 0 -0.014 -0.016 to -0.016 to Replace
6 f250
and transfer case -0.030 -0.060 0.060 0.060
Interference of idler gear and bear- +0.078 0 0.060 to 0.060 to
7 f140
ing +0.060 -0.025 0.103 0.103
Interference of idler gear bearing 0 -0.014 -0.016 to -0.016 to
8 f250
Interference of output shaft and +0.045 0 0.023 to 0.023 to
9 f120
bearing +0.023 -0.020 0.065 0.065
Interference of front output bearing 0 -0.014 -0.016 to -0.016 to
10 f215
0 +0.025
11 Interference of spacer and bearing f169 -0.045 to 0 -0.045 to 0
-0.02 0
Interference of rear output bearing 0 -0.014 -0.016 to -0.016 to
12 f250
and parking brake cover -0.030 -0.060 0.060 0.060
WA1200-6 60-25
Power train
Torque converter pump, transmission pump, brake cooling pump, brake pump
Torque converter pump, transmission pump, brake cooling pump, brake

pump 60-26
(quadruple type pump) 60-26
Model: SAR(4)200 + 200 + (3)71 + (2)40 60-26
60-26 WA1200-6
Power train
Torque converter pump, transmission pump, brake cooling pump, brake pump
Unit: mm

Type Standard clearance Allowable clearance
SAR (4) 200 0.14 to 0.19 0.22
SAR (4) 200 0.14 to 0.19 0.22

1 Side clearance
SAR (3) 71 0.10 to 0.15 0.19
SAR (2) 40 0.10 to 0.15 0.19
SAR (4) 200 0.06 to 0.14 0.20
Clearance between plain bearing SAR (4) 200 0.06 to 0.14 0.20
2 inside diameter and gear shaft out-
side diameter SAR (3) 71 0.06 to 0.149 0.20
Replace
SAR (2) 40 0.06 to 0.125 0.20

Standard dimen-
Type Tolerance Repair limit
sion
0
SAR (4) 200 14 –
-0.5
0
3 Pin driving depth SAR (4) 200 13 –
-0.5
0
SAR (3) 71 13 –
-0.5
SAR (2) 40 – – –
4 Spline shaft rotating torque 29.4 to 48.1 Nm {3.0 to 4.9 kgm}

Delivery
Standard Allowable
Revolutions pressure
Type MPa delivery delivery
(rpm)
(r/min.) (r/min.)
{kg/cm2}
Delivery SAR (4) 200 389 357
– Oil: EO10-CD –
Oil temperature: 45 to 55 °C SAR (4) 200 2.9 {30} 389 357
2000
SAR (3) 71 130 115
SAR (2) 40 20.6 {210} 70 62
WA1200-6 60-27
Power train
Drive shaft
Drive shaft 60-28
60-28 WA1200-6
Power train
Drive shaft
WA1200-6 60-29
Power train
Center support
Center support 60-30
Unit: mm

Clearance between case and bear- dimension Shaft Hole clearance clearance
1
ing 0 -0.022 -0.051 to
230 0.011
-0.030 -0.051 0.008
Clearance between case and bear- 0 -0.022 -0.051 to Replace
2 215 0.011
ing -0.030 -0.051 0.008
Clearance between coupling +0.052 0 -0.077 to
3 130 -0.024
shaft and bearing +0.027 -0.025 -0.027
Clearance between coupling +0.045 0 -0.065 to
4 120 -0.020
shaft and bearing +0.023 -0.020 -0.023
5 Wear of oil seal contacting surface 0
160 -0.160 Repair chrome plat-
-0.100
ing or replace
0
6 Wear of oil seal contacting surface 160 -0.160
-0.100
60-30 WA1200-6
Power train
Center support
WA1200-6 60-31
Power train
Differential
Differential 60-32
60-32 WA1200-6
Power train
Differential
Unit: mm

Clearance of side bearing outer dimension Shaft Hole clearance clearance
1
race of differential gear ass'y 0 +0.015 -0.016 to
280 –
-0.018 -0.016 0.032
Clearance of side bearing inner +0.100 0 -0.125 to
2 180 –
race of differential gear ass'y +0.075 -0.025 -0.075
Clearance of outer race of pinion +0.025 -0.025 -0.101 to
3 273.05 –
shaft bearing 0 -0.076 -0.025
Clearance of inner race of pinion +0.025 +0.025 -0.025 to
4 120.65 –
shaft bearing +0.003 0 0.022
Clearance of outer race of pinion +0.051 -0.025 -0.127 to
5 374.65 –
shaft bearing 0 -0.076 -0.025
Clearance of inner race of pinion +0.064 +0.025 -0.064 to Replace
6 161.925 –
shaft bearing +0.038 0 -0.013
Clearance of outer race of differen- 0 -0.028 -0.068 to
7 160 –
tial pinion gear bearing -0.025 -0.068 -0.003
Clearance of inner race of differen- +0.013 0 -0.028 to
8 90 –
tial pinion gear bearing -0.009 -0.015 0.009
Clearance of outer race of differen- 0 -0.028 -0.068 to
9 140 –
tial pinion gear bearing -0.018 -0.068 -0.010
Clearance of inner race of differen- +0.013 0 -0.028 to
10 90 –
tial pinion gear bearing -0.009 -0.015 0.009
Clearance between differential car- 0 +0.070
11 540 0 to 0.140 –
rier and cage -0.070 0
Clearance between spider and dif- 0 +0.030
12 70 0 to 0.060 –
ferential pinion -0.030 0
13 Backlash of bevel gear 0.43 to 0.61
14 Backlash of differential gear 0.31 to 0.40
15 Preload of pinion bearing 7.8 to 35.3 N {800 to 3,600 kg}

Adjust
16 Preload of side bearing 15.7 to 31.4 N {1,600 to 3,200 kg}
17 Back facial runout of bevel gear 0.13

Standard shim thickness for differ-
18 1.3
ential cage
WA1200-6 60-33
Power train
Differential
Unit: mm

1 Thickness of side gear washer
9.0 8.5
Replace
2 Wear of oil seal contacting surface 160 (0/-0.100) 159.84
60-34 WA1200-6
Power train
Differential
WA1200-6 60-35
Power train
Final drive
Final drive 60-36
60-36 WA1200-6
Power train
Final drive
Unit: mm

Clearance between planetary shaft dimension Shaft Hole clearance clearance
1
and bearing +0.018 0 -0.038 to
90
0 -0.020 0
Clearance between planetary gear 0 -0.035 -0.075 to
2 155 –
and bearing -0.025 -0.075 -0.010
Clearance between planetary shaft +0.041 +0.025 -0.041 to
3 99.982 –
and bearing +0.026 0 -0.001
Clearance between planetary +0.025 -0.051 -0.076 to
4 190.5 –
gear and bearing 0 -0.005 -0.005
Clearance between ring gear hub +0.127 +0.051 -0.127 to
5 479.425 –
and bearing +0.076 0 -0.025
Clearance between wheel hub and +0.076 -0.050 -0.206 to
6 679.45 –
bearing 0 -0.130 -0.050
Clearance between axle housing -0.020 +0.051 -0.020 to
7 409.575 –
and bearing -0.060 0 0.111
Clearance between wheel hub and +0.051 -0.044 -0.165 to
8 546.1 – Replace
bearing 0 -0.114 -0.044
Ring gear mounting
9
retainer thickness 40 ±0.1 39.6
10 Thrust shaft length (*) 12 ±0.1 11.1
Standard clearance Allowable clearance

Backlash between planetary gear
11
and sun gear 0.27 to 0.65 –
12 0.30 to 0.78 –
and ring gear
13 0.29 to 0.72 –
and sun gear
14 0.32 to 0.88 –
and ring gear
Standard thickness of shim for
15 2.4
wheel hub
*: Correct the surface roughness using sand paper and the like when it is reused.
WA1200-6 60-37
Steering system
Steering pump

Steering pump 60-38
Model: HPV160 + 160 + SAR(2)71 + 63 60-38
a See the section of switch pump for pump HPV160+160.
60-38 WA1200-6
Steering system
Switch pump
Switch pump 60-39

Model: HPV160 + 160 + SAR(3)125 + 100 60-39
WA1200-6 60-39
Steering system
Switch pump
Model: HPV160 + 160 60-40
60-40 WA1200-6
Steering system
Steering demand valve 60-41
WA1200-6 60-41
Steering system
Unit: mm

Steering spool Free length Free length
1 length load load
return spring
74.5 N 58.8 N
41.8 38.0 –
{7.6 kg} {6 kg}
Load check valve 8.8 N 7.0 N
2 20.9 13.2 –
spring {0.9 kg} {0.71 kg}
Demand spool 410 N 328 N
3 90.8 83.0 –
Replace
Surge cut 182.4 N 145.1 N
4 24.0 22.19 –
relief valve spring {18.6 kg} {14.8 kg}
Main relief valve 182.4 N 145.1 N
5 24.0 22.19 –
spring {18.6 kg} {14.8 kg}
Overload 590 N 471 N
6 39.5 35.7 –
relief valve spring {60.2 kg} {40.8 kg}
Check valve 8.8 N 7.0 N
7 20.9 13.2 –
60-42 WA1200-6
Steering system
Diverter valve
Diverter valve 60-43
Unit: mm

1 Clearance between body and spool
-0.023 +0.015 0.020 to
40 –
-0.005 +0.007 0.030
Standard dimension Tolerance
Free length Free length Replace
2 Spool return spring length load load
217 N 206 N
122.6 84 120.7
{22.1 kg} {21.0 kg}
5.59 N 5.3 N
3 Check valve spring 79.2 54.5 77.9
{0.57 kg} {0.54 kg}
4.9 N 4.6 N
4 Check valve spring 79.2 57.5 77.9
{0.50 kg} {0.47 kg}
WA1200-6 60-43
Steering system
Steering cylinder mount
Steering cylinder mount 60-4
Unit: mm

Clearance between bushing and
1 pin at the connection of steering
cylinder rod and the frame -0.043 +0.025 0.131 to
160 1.0
-0.106 0 0.043
-0.043 +0.025 0.131 to
2 pin at the connection of steering 160 1.0
-0.106 0 0.043
cylinder bottom and the frame
Standard clearance Replace
Boss width Hinge width
Connecting portion of steering cyl- (clearance of a + b)
3
inder and front frame
120 (0/-0.25) 135 (+1/0) 0 to 3.25
Connecting portion of steering cyl-
4 120 (0/-0.25) 135 (+1/0) 0 to 3.25
inder rod and rear frame
5 Spacer width
7.0 ±0.5 –
60-44 WA1200-6
Steering system
Steering cylinder
Steering cylinder 60-45
Unit: mm

Clearance between steering cylin- dimension Shaft Hole clearance clearance
1
der rod and bushing -0.043 +0.277 0.104 to
140 0.683
-0.106 +0.061 0.383
Clearance between piston rod -0.043 +0.025 0.043 to
2 160 1.0 Replace
mounting pin and bushing -0.106 0 0.131
Clearance between cylinder bottom -0.043 +0.025 0.043 to
3 160 1.0
mounting pin and bushing -0.106 0 0.131
4 Cylinder bore +0.2
225 –
0
WA1200-6 60-45
Steering system
Steering cylinder
a Each dimension indicates the one before bushing is mounted.

Unit: mm
No. Portion Basic dimension
5 Inner diameter of bushing press fitting portion on the rod side 255 (-0.036/-0.088)
Steering cylinder
6 Inner diameter of bushing press fitting portion on the bottom side 255 (-0.036/-0.088)
60-46 WA1200-6
Steering system
Emergency steering pump
Emergency steering pump 60-47

Model: SAM(3)100 + 100 60-47
Unit: mm

Type Standard clearance Allowable clearance
Clearance between gear case and
1
side plate SAM3-100 0.10 to 0.15 0.19
Clearance between needle bearing Replace
2 bore and gear shaft outside diame- SAM3-100 0.020–0.043 0.075
ter
3 Pin driving depth 14 (0/-0.5)
4 Spline shaft rotating torque 13.7 to 23.5 Nm {1.4 to 2.4 kgm} –

Delivery
Standard Allowable
Rotation pressure
Delivery Type delivery delivery
speed (rpm) MPa
– oil EO10-CD (r/min.) (r/min.) –
{kg/cm2}
Oil temperature: 45 to 55 °C
20.6
SAM3-100 2,000 352 312
{210}
WA1200-6 60-47
Brake system
Brake valve
Brake system 60-48

Brake valve 60-48
(R.H.) 60-48
Unit: mm

Clearance between pedal mounting dimension Shaft Hole clearance clearance
1
hole and bracket hole -0.025 +0.1 0.175 to
10 0.25
-0.075 0 0.025
-0.025 +0.1 0.175 to
2 Clearance between roller and pin 10 0.25
-0.075 0 0.025
3 Outside diameter of roller 0
30 29.2
-0.5
4 Control spring length load load
4.6 N
34 33.5 33
{0.47 kg}
11.8 N
5 Control spring 46.3 46.0 45.3
{1.2 kg}
60.8 N
6 Return spring 86.2 58 78
{6.2 kg}
17.7 N
7 Spring 17 16.5 16.2
{1.8 kg}
16.7 N
8 Return spring 31.5 19.5 28
{1.7 kg}
60-48 WA1200-6
Brake system
Brake valve
(L.H.) 60-49
Unit: mm

Clearance between pedal mounting dimension Shaft Hole clearance clearance
1
hole and bracket hole -0.025 +0.1 0.175 to
10 0.25
-0.075 0 0.025
-0.025 +0.1 0.175 to
2 Clearance between roller and pin 10 0.25
-0.075 0 0.025
3 Outside diameter of roller 0
30 29.2
-0.5
4 Control spring length load load
93.2 N
34 21.8 33
{9.5 kg}
45.9 N
5 Control spring 46.3 34.3 45.3
{46.8 kg}
60.8 N
6 Return spring 86.2 58 78
{6.2 kg}
16.7 N
7 Return spring 31.5 19.5 28
{1.7 kg}
WA1200-6 60-49
Brake system
Slack adjuster
Slack adjuster 60-50
Unit: mm

Clearance between body and pis- dimension Shaft Hole clearance clearance
1
ton -0.030 +0.074 0.030 to
55 0.25
-0.076 0 0.150
2 Slack adjuster spring length load load
117.7 N
246 88 – –
{12 kg}
123.6 N
3 Check valve spring 44.8 38 – –
{12.6 kg}
60-50 WA1200-6
Brake system
Brake
Brake 60-51
Unit: mm

1 Return spring length load load
1,600 N 1,520 N
124.9 104.8 123.0
{163 kg} {154.9 kg}
2 Thickness of plate
3.1 ±0.1 2.85
3 Thickness of disc 6.7 ±0.3 6.2

0 Replace
4 Wear of seal contacting surface 850 –
-0.230
Wear of piston seal contacting sur- +0.140
5 839.5 –
face 0
Wear of piston seal contacting sur- +0.140
6 864 –
face 0
Standard strain volume Repair limit
7 Strain of plate friction surface
0.5 (maximum) 0.7
8 Strain of disk friction surface 0.7 (maximum) 0.9
WA1200-6 60-51
Brake system
Parking brake
Parking brake 60-52
Unit: mm

No.1 clutch spring Free length Free length
1 length load load
(x14)
1,008.5 N 958.1 N
132 83.8 128
{102.81 kg} {97.67 kg}
No.2 clutch spring 1,627.5 N 1,546.1 N
2 130 83.8 126.1
(x14) {165.9 kg} {157.61 kg}
Total assembly thickness of 16
3
brake disks and 17 separator plates 119.2 ±0.39 113.9
Thickness 4.0 ±0.05 3.9

4 Separate plate Replace
Distortion – 0.20 0.6
Thickness 3.2 ±0.08 2.975

Lining
groove +0.25
5 Brake disc depth (one
0.45 0.338
0
side)
Lining
thickness 0.7 ±0.16 –
(one side)
Wave spring load
6 626.6 N {63.9 kg} ±176.5 N {±18 kg} 532.6 N {54.3 kg}
(height: 3.2 mm)
60-52 WA1200-6
Brake system
Parking brake
WA1200-6 60-53
axle mount

axle mount 60-54
60-54 WA1200-6
axle mount
Unit: mm

Tolerance Repair limit
Standard
Clearance between shaft and hole Standard Allowable
dimension Shaft Hole
1 of the front support clearance clearance
(before bushing press fit) +4.000 +0.175 -4.000 to
540 –
0 0 +0.175
Clearance between shaft and hole
-0.076 +0.522 -0.270 to
2 of the front support 530 1.6
-0.185 -0.346 0.707
(after bushing press fit)
Clearance between shaft and hole
+4.000 +0.175 -4.000 to
3 of the rear support 540 –
0 0 +0.175
(before bushing press fit)
Clearance between shaft and hole Replace
-0.076 +0.522 -0.270 to
4 of the rear support 530 1.6
-0.185 -0.346 0.707
(after bushing press fit)
5 Thickness of thrust washer
8 ±0.2 –
-0.21
6 Thickness of thrust plate 53 –
-0.35
7 Thickness of rear bushing 5 ±0.1 –
8 Thickness of front bushing 5 ±0.1 –
WA1200-6 60-55
Center hinge pin
Center hinge pin 60-56
60-56 WA1200-6
Center hinge pin
Unit: mm

Standard
Standard Allowable
Clearance between lower hinge dimension Shaft Hole
1 clearance clearance
pin and bushing
-0.050 +0.078 0.050 to
228.46 –
-0.079 0 0.157
Clearance between lower hinge pin -0.050 +0.072 0.050 to
2 228.46 1.0
and spacer (small) -0.079 0 0.151
3 228.46 –
and bearing -0.079 0 0.104
4 228.46 1.0
and bearing (large) -0.079 0 0.151
Clearance between lower hinge -0.056 +0.099 0.056 to
5 305.0 –
spacer (large) and bushing -0.137 0 0.236
Clearance between front frame and +0.025 -0.074 -0.151 to
6 269.875 –
upper hinge bearing 0 -0.126 -0.074
Clearance between upper hinge pin -0.050 +0.072 0.050 to
7 187.325 –
and rear frame -0.079 0 0.151
Clearance between upper hinge pin -0.050 +0.072 0.050 to
8 187.325 –
and bearing -0.079 0 0.151
Clearance between front frame and +0.051 -0.109 -0.217 to Replace
9 431.8 –
lower hinge bearing 0 -0.166 -0.109
Clearance between rear frame of -0.050 +0.072 0.050 to
10 248 –
upper hinge portion and bushing -0.079 0 0.151
Clearance between upper hinge +0.26 +0.072 -0.260 to
11 210 –
seal press-fit portion +0.16 0 -0.088
Clearance of lower hinge pin +0.260 +0.081 -0.260 to
12 310 –
seal press-fit portion +0.160 0 -0.079
Clearance between lower hinge +0.242 +0.072 -0.242 to
13 250 –
bushing and frame (upper side) +0.196 0 -0.124
Clearance between lower hinge +0.325 +0.089 -0.325 to
14 325 –
bushing and frame (lower side) +0.268 0 -0.179
15 Lower hinge spacer (small) height
134.5 ±0.1 –
16 Lower hinge spacer (large) height 224.5 ±0.1 –

Thickness of lower hinge and
17 45 ±0.8 –
retainer
Standard shim value for lower hinge
18 3.0
and retainer
Standard shim value for lower hinge
19 2.52 Adjust
and retainer
Standard shim value for upper
20 2.62
hinge and retainer
WA1200-6 60-57
Center hinge pin
Front center hinge
Rear center hinge
60-58 WA1200-6
Hydraulic system
No.1 work equipment pump

No.1 work equipment pump 60-59
Model: HPV160 + 160 60-59
WA1200-6 60-59
Hydraulic system
No.1 work equipment pump (HPV160 + 160) 60-60
60-60 WA1200-6
Hydraulic system
WA1200-6 60-61
Hydraulic system
No.2 work equipment pump 60-62

Model: HPV95 + 95 + SAL(2)40 60-62
60-62 WA1200-6
Hydraulic system
No.2 work equipment pump (HPV95 + 95) 60-63
WA1200-6 60-63
Hydraulic system
60-64 WA1200-6
Hydraulic system
PPC relief valve
PPC relief valve 60-65
Unit: mm

Standard dimension Allowable limit
1 Main valve spring length load load
17.6 N 13.7 N Replace
44.5 32.5 –
{1.79 kg} {1.4 kg}
37.0 N 29.6 N
2 Poppet spring 31 26.7 –
{3.77 kg} {3.0 kg}
WA1200-6 60-65
Hydraulic system
Pump control relief valve
Pump control relief valve 60-6
Unit: mm

1 Main valve spring length load load
17.6 N 13.7 N Replace
44.5 32.5 –
{1.79 kg} {1.4 kg}
37.0 N 29.6 N
2 Poppet spring 31.0 26.7 –
{3.77 kg} {3.0 kg}
60-66 WA1200-6
Hydraulic system
Work equipment control valve 60-67
WA1200-6 60-67
Hydraulic system
Unit: mm

1 Spool return spring length load load
431 N 345 N
69.9 63.0 –
{44.0 kg} {35.2 kg}
607.6 N 486.1 N
2 Spool return spring 77.0 71.5 – If damaged or
{62 kg} {49.6 kg}
61.6 N 49.0 N deformed, replace
3 Spool return spring 79.7 78.5 – spring
{6.28 kg} {5.0 kg}
18.8 N 14.7 N
4 Check valve spring 78.2 52.0 –
{1.92 kg} {1.50 kg}
137 N 110 N
5 Spring of float selector valve 53.0 42.1 –
{14.0 kg} {11.2 kg}
49.0 N 39.2 N
6 Spring of unload valve 82.7 47.0 –
{5.0 kg} {4.0 kg}
60-68 WA1200-6
Work equipment

Work equipment linkage 60-69
WA1200-6 60-69
Work equipment
a The left side of the machine is shown as an example in the following figure.
a The length of the collars (b: inside of the machine; c: outside of the machine) are different (section D-D).
60-70 WA1200-6
Work equipment
Unit: mm

Standard
Clearance between shaft hole Standard Allowable
dimension Shaft Hole
1 bushing and pin of the both ends of clearance clearance
the bucket link -0.043 +0.401 0.352 to
180 0.1
-0.106 +0.309 0.507
-0.050 +0.519 0.471 to
2 pin at the connection of lift arm and 240 0.1
-0.122 +0.421 0.641
bucket
-0.056 +0.605 0.549 to
3 pin at the connection of lift arm and 280 0.1
-0.137 +0.493 0.742
frame
Clearance between bushing and Replace
-0.043 +0.242 0.239 to
4 pin at the connection of bucket cyl- 180 0.1 Replace when the
-0.106 +0.196 0.348
inder rod and bell crank pin has galling too.
-0.043 +0.401 0.352 to
5 pin at the connection of bucket cyl- 180 0.1
-0.106 +0.309 0.507
inder bottom and frame
-0.050 +0.519 0.471 to
6 pin at the connection of bell crank 240 0.1
-0.122 +0.421 0.641
and lift arm
-0.050 +0.519 0.471 to
7 pin at the connection of lift arm cyl- 240 0.1
-0.122 +0.421 0.641
inder bottom and frame
-0.050 +0.519 0.471 to
8 pin at the connection of lift arm cyl- 240 0.1
-0.122 +0.421 0.641
inder rod and lift arm
Bush width Collar width Collar width
Pin length
Connection portion of bucket cylin- a b c
9
der and bell crank
393 ± 0.3 209.5 ± 0.1 91.3 ± 0.1 91.3 ± 0.1
Connection portion of lift arm and
10 655 ± 0.3 304.5 ± 0.1 174.7 ± 0.1 174.7 ± 0.1
frame
11 594 ± 0.3 349.4 ± 0.1 121.8 ± 0.1 121.8 ± 0.1
bucket
Replace the bush-
Connection portion of bucket link
12 479 ± 0.3 259.5 ± 0.1 109.3 ± 0.1 109.3 ± 0.1 ing and the collar
and bucket
when the clearance
Connection portion of bell crank
13 443 ± 0.3 259.5 ± 0.1 91.3 ± 0.1 91.3 ± 0.1 of d + e reaches 2.5
and bucket link
mm.
Connection portion of lift arm cylin-
14 580.5 ± 0.3 274.4 ± 0.1 121.8 ± 0.1 183.3 ± 0.1
der and frame
Connection portion of bell crank
15 594 ± 0.3 349.4 ± 0.1 121.8 ± 0.1 121.8 ± 0.1
and lift arm
Connection portion of bucket cylin-
16 430 ± 0.3 209.5 ± 0.1 109.3 ± 0.1 109.3 ± 0.1
der and frame
17 479 ± 0.3 274.4 ± 0.1 101.8 ± 0.1 101.8 ± 0.1
lift arm cylinder
18 Wear of bucket teeth
504 340
19 Wear of wear plate 70 12

Replace
20 Wear of edge protector 189 40
21 Wear of side edge protector 83 30
WA1200-6 60-71
Work equipment
Front frame Lift arm cylinder
Lift arm, bell crank, bucket link Bucket cylinder
Bucket
60-72 WA1200-6
Work equipment
a Each dimension indicates the one before bushing is mounted.

Unit: mm
No. Item
22 Inner diameter of lift arm mounting pin portion 340 (+0.089/0)

inner diameter of pin mounting portion on the bucket cylin-
23 Front frame 230 (+0.072/0)
der bottom side
Inner diameter of pin mounting portion on the lift arm cylin-
24 300 (+0.081/0)
der bottom side
25 Inner diameter of front frame mounting portion 340 (+0.089/0)
Inner diameter of pin mounting portion on the lift arm cylin-
26 300 (+0.081/0)
der rod side
Lift arm
27 Inner diameter of bell crank mounting pin portion 300 (+0.081/0)
28 Inner diameter of bucket mounting pin portion 300 (+0.081/0)
29 Inner diameter of lift arm mounting portion 300 (+0.081/0)

Bore of pin mounting portion on the bucket cylinder rod
30 Bell crank 230 (+0.072/0)
side
31 Inner diameter of bucket link mounting pin portion 230 (+0.072/0)
32 Inner diameter of bell crank mounting portion 230 (+0.072/0)

Bucket link
33 Inner diameter of bucket mounting portion 230 (+0.072/0)
34 Inner diameter of pin mounting portion on the rod side 300 (+0.081/0)
Lift arm cylinder
35 Inner diameter of pin mounting portion on the bottom side 300 (+0.081/0)
36 Inner diameter of pin mounting portion on the rod side 230 (+0.072/0)
Bucket cylinder
37 Inner diameter of pin mounting portion on the bottom side 230 (+0.072/0)
38 Inner diameter of bucket link mounting pin portion 230 (+0.072/0)

Bucket
39 Inner diameter of lift arm mounting portion 300 (+0.081/0)
WA1200-6 60-73
Work equipment
Bucket positioner, remote positioner
Bucket positioner, remote positioner 60-74
Unit: mm

Clearance of bucket positioner
1 3 to 5
switch
Adjust
Bucket positioner protector to
2 0.5 to 1
switch tip
3 Lift arm angle sensor See the Inspection and Adjustment section for adjustment. –
60-74 WA1200-6
Work equipment
Work equipment cylinder
Work equipment cylinder 60-75

Lift arm cylinder 60-75
Unit: mm

Standard
Standard Allowable
Clearance between lift arm cylinder dimension Shaft Hole
rod and bushing
-0.050 +0.247 0.084 to
240 0.669
-0.122 +0.034 0.369
2 240 1.0 Replace
mounting pin and bushing -0.122 +0.421 0.641
3 240 1.0
360 –
0
WA1200-6 60-75
Work equipment
Work equipment cylinder
Bucket cylinder 60-76
Unit: mm

Standard
Standard Allowable
Clearance between bucket cylinder dimension Shaft Hole
rod and bushing
-0.043 +0.216 0.091 to
180 0.622
-0.106 +0.048 0.322
2 180 1.0 Replace
3 180 1.0
300 –
0
60-76 WA1200-6
Electrical system

Work equipment control lever 60-7
a Do not disassemble this part. If it is disassembled, it needs to be adjusted to maintain its performance.
WA1200-6 60-77
Electrical system
60-78 WA1200-6
SEN0547531-00 80-1
WA1200-6
WHEEL LOADER
Shop Manual 8-01
WA1200-6

WA1200-6 60001 and up
80 Appendix 80-1
WA1200-6 80-1
Contents
Contents 80-2
80 Appendix
Air conditioner ......................................................................................................................... 80- 3
Precautions for refrigerant ................................................................................................... 80- 3
Configuration and function of refrigeration cycle.................................................................. 80- 4
Outline of refrigeration cycle ................................................................................................ 80- 5
Control system ..................................................................................................................... 80- 7
Air conditioner components ................................................................................................. 80- 11
Compressor ......................................................................................................................... 80- 18
Electric fan and condenser .................................................................................................. 80- 19
Receiver drier....................................................................................................................... 80- 21
Service tools ........................................................................................................................ 80- 22
Troubleshooting procedures ................................................................................................ 80- 29
Interview and confirmation of failure symptom..................................................................... 80- 30
Basic checks ........................................................................................................................ 80- 31
Troubleshooting ................................................................................................................... 80- 32
Checking of refrigeration cycle............................................................................................. 80- 38
Troubleshooting for unusual noise....................................................................................... 80- 46
Electrical system .................................................................................................................. 80- 47
Parts replacement................................................................................................................ 80- 49
Periodic inspection and maintenance .................................................................................. 80- 52
Testing and adjusting compressor belt tension.................................................................... 80- 56
80-2 WA1200-6
Air conditioner
Precautions for refrigerant
Air conditioner 80-3

Precautions for refrigerant 80-3
k Collect the air conditioner refrigerant (R134a)

from air conditioner circuit before discon-
necting air conditioner hose to replace air
conditioner unit, air conditioner compressor
or receiver drier and so on.
a Ask a qualified shop for collecting, adding and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the at-
mosphere.
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches
your skins, you may suffer from frostbite. Ac-
cordingly, put on protective goggles, gloves
and working suits with long sleeves while
you are collecting the refrigerant (R134a) or
filling the air conditioner circuit with the re-
frigerant (R134a). Collecting and filling work
must be conducted by a qualifier person.
WA1200-6 80-3
Air conditioner
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle 80-4

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator cab In operator cab
Location Engine compartment Front of radiator (Built in air conditioner (Built in air conditioner
unit) unit)
Circulates refrigerant
gas and increases its Lowers temperature and Evaporates refrigerant to
Condenses refrigerant
temperature and pres- pressure of refrigerant liq- absorb heat from air
to discharge heat
sure so that it can be uid and gas for easy evap- around evaporator, and
Function absorbed in evaporator.
liquefied easily in con- oration with throttle. cool the air.
(condensation of refrig-
denser. Controls flow rate, too. (Evaporation of refriger-
erant)
(Compression of (Throttle of refrigerant) ant)
refrigerant)
Gas o Gas Gas o Liquid
Liquid o Liquid and gas Liquid and gas o Gas
State of refriger-
ant Adiabatic compres- Cnstant pressure
Adiabatic expansion Cnstant pressure change
sion change
80-4 WA1200-6
Air conditioner
Outline of refrigeration cycle
Outline of refrigeration cycle 80-5

The refrigeration cycle is comprised of 4 cycles. The refrigerant is circulated while repeatedly vaporizing and
liquefying.
1. Compression (Compressor) The expansion valve controls the refrigerant

The compressor sucks in the refrigerant that has feed rate so that the optimum quantity of liquid
been vaporized in the evaporator and refrigerant is supplied to the evaporator.
compresses it into a state where it can be easily
liquefied at the ambient temperature. (*1) Throttle action
The gaseous refrigerant sucked into the If there is a narrow section in the passage
compressor cylinder is compressed to a temper- through which liquid is flowing at a constant rate,
ature and pressure at which it can be easily a resistance to the flow will be generated.
liquefied when cooled to the ambient tempera- The liquid expands when it passes through the
ture. narrow section and rushes into the passage
where the sectional area is larger, and conse-
2. Condensation (Condenser) quently, its pressure and temperature are
The condenser cools and liquefies the high pres- reduced.
sure and high-temperature gaseous refrigerant No heat is transferred from or to the outside
sent from the compressor. during the throttle action.
The heat released to the outside from the
condenser is called condensation heat. 4. Evaporation (Evaporator)
The amount of condensation heat is the sum The evaporator evaporates the liquid refrigerant
total of the heat absorbed by the evaporator from (superheated vapor).
the air in the cab and the quantity of the work The refrigerant evaporates, while absorbing an
applied (the value converted into a heat quantity) amount of heat necessary for evaporation (evap-
by compression of the compressor. oration heat) from the air around the cooling fins
The refrigerant liquefied in the condenser is sent (air in the cab).
to the receiver drier, where moisture is removed. After the heat has been removed, the cooled air
In the compression cycle, the gaseous refrig- is sent into the cab by the blower fan, reducing
erant and liquid refrigerant coexist. the temperature inside the cab.
The temperature (condensation temperature) The mist refrigerant that has been sent from the
and the pressure (condensation pressure) at expansion valve coexists with the evaporated
which the gaseous refrigerant is liquefied are refrigerant in the evaporator
proportional to each other. The temperature (evaporation temperature) and
the pressure (evaporation pressure) at which the
Reference: The pressure varies depending on liquid refrigerant is evaporated are proportional
the condensation temperature of the refrigerant. to each other.
The compressor sucks in the evaporated refrig-
3. Expansion (Expansion valve) erant in order to keep the pressure level in the
The expansion valve reduces the liquid refrig- evaporator as low as possible so that the liquid
erant pressure to a level where liquid refrigerant refrigerant can be evaporated at a much lower
can be easily evaporated by the throttle action temperature.
(*1).
The action of reducing the liquid refrigerant pres- Relationship between refrigerant and defective
sure to a level where it can be easily evaporated air conditioning 80-5
before it is sent to the evaporator is called q The refrigerant circulates in the refrigeration cir-
expansion. cuit while repeating the refrigeration cycle to ex-
The expansion valve, which reduces the refrig- pel the heat from inside the cab.
erant pressure, also adjusts the refrigerant flow q If there is an insufficient quantity of refrigerant,
rate simultaneously. all of it will be evaporated while it is passing
The quantity of the liquid refrigerant that can be through the evaporator. This causes evaporator
evaporated in the evaporator depends on the efficiency to deteriorate, which will result in de-
amount of heat (refrigeration load) to be fective air conditioning.
removed under the specific evaporation temper-
ature (evaporation pressure).
WA1200-6 80-5
Air conditioner
Outline of refrigeration cycle
q If there is excessive refrigerant, not all of it will be

evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the
compressor to compress the liquid and may
damage the components.
q If water gets into the refrigeration circuit, it will
freeze at a small hole in the expansion valve,
lower the refrigerant flow, and may result in de-
fective air conditioning.
80-6 WA1200-6
Air conditioner
Control system
Control system 80-7
q To make best use of the performance and main-

tain a comfortable environment in the operator's
cab, the air conditioner has various control sys-
tems including the air temperature control, air
flow control, air vent mode selection, etc..
1. Outline of controls 80-7
1) Control panel
a The control panel is integrated with the controller.
1. Temperature control switch

q This switch allows adjustment of the air tem-
perature continuously from low temperatures
to high temperatures.
2. FRESH/RECIRC air changeover switch
q This switch allows switching the air source
between fresh air and recirculation air.
3. Blower switch
q This switch allows adjustment of air flow rate
in four levels.
4. Air conditioner switch
q Use this switch to turn "Cooling" or "Dehu-
midification" function ON and OFF.
5. Mode selector switch
q Use this switch to select effective air vents.
WA1200-6 80-7
Air conditioner
Control system
2) Details of control
q The function of the main controls for the air conditioner are shown in the following table.
Item Control details
q This temperature control is performed by automatically switching ON and

1. Temperature control OFF the compressor at a set temperature depending on the temperature
of the air cooled by the evaporator, which is monitored using a thermistor.
q This air flow control is achieved by adjusting the blower motor speed in
2. Air flow control
four levels.
q This changeover is realized by controlling the fresh air and recirculated air
3. FRESH/RECIRC air changeover selector damper.
control q This selector is realized by controlling the air vent selection damper for
cooling and heating.
q This control is performed to prevent frosting of the evaporator.
4. Anti-icing control
q A thermistor is used.
5. Compressor control q This control is used to detect abnormal refrigerant pressures.
2. Temperature control (thermistor) 80-8

Thermistor (1) is a semiconductor whose resis-
tance varies significantly with temperature. As
shown in the drawing, its resistance decreases
as the temperature rises, and its resistance in-
creases as the temperature lowers.
Thermistor (1) is installed to the rear of the evap-
orator to detect the temperature of the air after it
passes through the evaporator.
The temperature control switch is provided on

the control panel.
To control the temperature, the signal from
temperature control switch (indicating the
desired temperature) and that from the therm-
istor are compared at the air conditioner ampli-
fier, and based on the comparison results, the
compressor is turned ON and OFF via the
magnetic clutch.
The signal from the thermistor is also used for
anti-icing of the evaporator (see "5. Anti-icing
control").
80-8 WA1200-6
Air conditioner
Control system
3. Air flow control 80-9 5. Anti-icing control 80-9

The flow of air blown into the cab is controlled by When warm air passes through the evaporator
changing the blower motor speed. fins, the moisture in the air condenses as the air
The blower motor is a ferrite motor, and its speed is cooled, generating waterdrops on the evapo-
(air flow) is controlled by changing the voltage rator fins.
using resistors. If the fins are cooled to a temperature below
0 °C, the waterdrops may freeze or accumulate
as frost. If this icing occurs, the heat exchange
efficiency of the evaporator is degraded resulting
in lowered cooling performance.
The thermostat type anti-icing system is
explained below.
Thermostat type anti-icing system (ON/OFF

switch)
Evaporator sensor (1) installed to the rear of the
evaporator detects the temperature of the evap-
orator, and the temperature signal is used to turn
off the air compressor before icing occurs at the
evaporator.
[Reference]
q Motor speed
Speed (N) of a DC motor is proportional to
voltage (V) at motor terminals, and inversely
proportional to magnetic flux (f).
Speed N = K·V/f
Since magnetic flux (f) of a DC motor is
constant, its speed can be controlled by
changing the voltage applied to the motor by
using resistors connected in series.
4. FRESH/RECIRC air changeover control 80-9

When FRESH/RECIRC air changeover switch
on the control panel is operated, the damper
moves to switch the mode.
FRESH air mode: Outside air is introduced.
Usually set the switch to this position.
RECIRC air mode: Use this mode when outside
air is unclean or you want to accelerate
cooling or heating.
WA1200-6 80-9
Air conditioner
Control system
6. Compressor control 80-10 1] Detecting abnormally high pressures

Judgment of abnormal refrigerant pressures If the pressure in the refrigeration cycle
If an abnormal pressure is detected by the pres- becomes abnormally high, it may cause
sure switch installed to the high-pressure side of failure or damage of the components.
the refrigerant cycle, the compressor is stopped The pressure switch becomes OFF state
to prevent problems in the refrigeration cycle if it detects a high pressure exceeding
components. approx. 3.1 MPa {32 kg/cm2}.
Commonly, the refrigerant pressure is detected
by a pressure switch installed between the 2] Detecting abnormally low pressures
receiver tank and the expansion valve on the If the refrigerant in the refrigeration cycle
high-pressure side. becomes extremely insufficient or
completely lost by leakage, the
compressor may seize if it is run in this
condition, due to insufficient lubrication
provided by the compressor oil.
Therefore, the pressure switch becomes
OFF state if it detects an abnormally low
pressure below approx. 0.2 MPa
{2.0 kg/cm2} on the high-pressure side.
1) Pressure switch
A "dual type" pressure switch is used for
detection of both abnormally high and low
pressures.
80-10 WA1200-6
Air conditioner
Air conditioner components
Air conditioner components 80-1
WA1200-6 80-11
Air conditioner
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Hot water valve
7. Refrigerant piping
8. Pressure switch
9. Sight glass
10. Charge port
11. Quick joint
12. Air conditioner unit
13. Air conditioner controller and control panel
14. Fresh air filter
15. Recirculation air filter
16. FRESH/RECIRC air changeover box
17. Vent selector box
18. Rear defroster ON/OFF knob
A: Front face vent

B: Side face vent
C: Foot vent
D: Front defroster vent
E: Rear defroster vent
Refrigerant R134a
Refrigerant refill capacity (g) 1,300 - 1,500
80-12 WA1200-6
Air conditioner
Air conditioner unit 80-13
19. Evaporator 25. Water valve

20. Heater core 26. Blower fan and blower motor
21. Expansion valve 27. Blower resistor
22. Thermistor
23. Servomotor F: Refrigerant inlet (from condenser)
24. Air mix door G: Refrigerant outlet (to condenser)
24-1. Cool door H: Hot water inlet
24-2. Hot door J: Hot water outlet
WA1200-6 80-13
Air conditioner
FRESH/RECIRC air changeover box 80-14
28. FRESH/RECIRC air changeover servomotor

29. FRESH/RECIRC air changeover door
30. Recirculation air filter (1)
31. Recirculation air filter (2)
80-14 WA1200-6
Air conditioner
Vent selector box 80-15
32. Vent (mode) selector servomotor

33. Vent (mode) selector door
Functions of components 80-15

q Evaporator
Evaporator (19) is cooled by the low-pressure
and low-temperature refrigerant gas sent from
expansion valve (12). Air from blower motor (26)
is cooled and dehumidified when passing
through the evaporator fins.
q Heater core
Heater core (20) is warmed by the hot water
(engine coolant) sent from the engine. Air from
blower motor (26) is warmed when passing
through the heater core fins.
WA1200-6 80-15
Air conditioner
q Expansion valve
A: When evaporator outlet temperature is high Structure 80-16

B: When evaporator outlet temperature is low q Box-type expansion valve (21) consists of nee-
C: From receiver drier (high-pressure refrig- dle valve (1a), spring (1b), etc.
erant) q Refrigerant gas (34) is sealed in the diaphragm
D: To compressor (low-pressure refrigerant) chamber (hatched area) outside diaphragm
(1a-1) of needle valve (1a).
19. Evaporator q The opening level of the needle valve (1a) is de-
21. Expansion valve termined based on the balance between the re-
1a. Needle valve action force exerted by the spring (1b) in a
1a-1. Diaphragm rightward direction, and the force (Fg) of the re-
1a-2. Thermoprobe frigerant gas (34) pushing the needle valve (1a)
1b. Spring through the diaphragm (1a-1) in a leftward direc-
34. Refrigerant gas tion.
q The refrigerant flow rate flowing from the receiv-
Outline 80-16 er drier to evaporator (19) is determined based
q Expansion valve (21) converts high-pressure on the opening of needle valve (1a).
and high-temperature liquid refrigerant sent from
the receiver drier to a mist of low-pressure and
low-temperature refrigerant through throttle ac-
tion.
q It controls the flow rate of refrigerant by changing
the level of throttling depending on the tempera-
ture in the cab.
q The temperature of the air blown out of the air
vent is adjusted according to the volume of re-
frigerant circulating in evaporator (19).
80-16 WA1200-6
Air conditioner
Operation 80-17 q Pressure switch

q Thermoprobe (1a-2) senses the refrigerant tem- a This pressure switch is installed to the air
perature after it passes through the evaporator conditioner tube on the floor.
(19). q Pressure switch (8) becomes "OFF" when
q The temperature of the refrigerant that has the refrigerant circuit pressure becomes ab-
passed through evaporator (19) is transferred to normally low or abnormally high.
the refrigerant gas (34) in the diaphragm cham- q When the pressure switch becomes "OFF",
ber (hatched area) through the thermoprobe the air conditioner controller sets the com-
(1a-2). pressor clutch relay to "OFF". As a result, the
q The pressure of the refrigerant gas (34) sealed in compressor's magnetic clutch is released
the diaphragm chamber (hatched area) changes and air conditioner components are protect-
in response to the temperature change of the ed.
thermoprobe (1a-2), which therefore changes
the force (Fg) pushing the needle valve (1a).
q The opening level of the needle valve (1a) is de-
termined based on the balance between the re-
action force exerted by the spring (1b) in a
rightward direction, and the force (Fg) of the re-
frigerant gas (34) pushing the needle valve (1a)
through the diaphragm (1a-1) in a leftward direc-
tion.
When outlet temperature of evaporator (19) is

high: 80-17
[When it is not cooled yet: Condition (A) in the
figure] 80-17
q The pressure of the refrigerant gas (34) in the di-
a LA or lower: Abnormally low pressure
aphragm chamber is high and the volume is in- a HA or higher: Abnormally high pressure
creased.
q The force (Fg) of the refrigerant gas (34) pushing
LA: 0.20 MPa {2 kg/cm2}
the needle valve (1a) increases and moves the LB: 0.02 MPa {0.2 kg/cm2}
needle valve (1a) to the left. HA: 3.14 MPa {32 kg/cm2}
q As a result, the opening level of the needle valve
HB: 0.59 MPa {6 kg/cm2}
(1a) is increased and the refrigerant flow rate to
the evaporator (19) is increased, resulting in in-
creased cooling capacity.
When outlet temperature of evaporator (19) is

low: 80-17
[When it is cooled already: Condition (B) in the
figure] 80-17
q The pressure of the refrigerant gas (34) in the di-
aphragm chamber is low and the volume is de-
creased.
q The force (Fg) of the refrigerant gas (34) pushing
the needle valve (1a) reduces and the force of
spring (1b) moves needle valve (1a) to the right.
q The opening level of the needle valve (1a) is re-
duced and the refrigerant flow rate to the evapo-
rator (19) is reduced, resulting in decreased
cooling capacity.
WA1200-6 80-17
Air conditioner
Compressor
Compressor 80-18
A: Refrigerant inlet (from air conditioner unit) Function 80-18

B: Refrigerant outlet (to condenser) q The compressor circulates the refrigerant and
compresses the gaseous refrigerant from the
1. Pulley evaporator to convert it into mist of high-pres-
2. Magnet clutch sure and high-temperature refrigerant so that it
3. Relief valve is easily regenerated (liquefied) at the normal
temperature.
q The air conditioner controller engages magnet
clutch (2) built in the compressor depending on
the evaporator temperature and refrigerant pres-
sure.
q When the magnet clutch is engaged, the power
of the engine rotates the compressor shaft along
with pulley (1) to drive the compressor.
Number of cylinders - bore x
stroke 10 - 29.5x22.7
(mm)
Piston capacity
155.3
(cc/rev)
Allowable maximum speed
6,000
(rpm)
Denso: ND-OIL8 (For
Compressor oil
R134a)
Compressor oil refill capacity
220
(cc)
80-18 WA1200-6
Air conditioner
Electric fan and condenser
Electric fan and condenser 80-19
1. Electric fan Specifications 80-19

2. Electric fan motor Fin pitch (mm) 4.0
3. Condenser
Core height x width x thick-
311.2x346x44
ness (mm)
A: Refrigerant inlet (from compressor) Max. operating pressure
B: Refrigerant outlet (to receiver drier) 3.6 {36}
(MPa {kg/cm2})
q Electric fan motor (2) drives electric fan (1) for

forced-cooling of condenser (3).
q If the condenser fins are crushed or is clogged
with dust, heat exchange efficiency is reduced
and complete liquefaction of refrigerant be-
comes impossible.
If the heat exchange efficiency is reduced, pres-
sure in the refrigerant circulation circuit will be
increased, applying extra load to the engine or
reducing the cooling effect. Take extreme care
not to crush or damage the fins when handling it
or performing daily inspection.
WA1200-6 80-19
Air conditioner
Electric fan and condenser
Function 80-20 2. Pressure switch

The condenser in the refrigeration cycle is used for The pressure switch becomes ON or OFF
liquefying gaseous refrigerant, by forcibly causing according to the refrigerant pressure.
heat exchange between the compressed, high-tem- ON: 1.52 MPa {15.5 kg/cm2}
perature and high-pressure gaseous refrigerant and
OFF: 1.23 MPa {12.5 kg/cm2}
outside air, by using the fan, etc.
The amount of heat removed from the gaseous re-

frigerant at the condenser depends on the amount
of heat absorbed from the cabin air at the evapora-
tor and the workload of the compressor compress-
ing the gas. Therefore, the heat dissipation effect of
the condenser has a direct and major effect on cool-
ing of the cabin air.
q Pressure switch
1. 2-speed control of electric fan motor

The electric condenser fan is controlled in 2
speeds, depending on the refrigerant pressure
on the high-pressure side.
When the pressure of high-pressure side
exceeds 1.52 MPa {15.5 kg/cm2}, the pressure
switch becomes ON and the motor is powered
by 24 V power. Thus, the fan motor runs at the
high-speed setting.
When the pressure of high-pressure side falls
below 1.23 MPa {12.5 kg/cm2}, the pressure
switch becomes OFF and the motor is powered
by the voltage dropped by the resistor. Thus, the
fan motor runs at the low-speed setting.
This is to extend the life of the fan motor and to
save energy.
80-20 WA1200-6
Air conditioner
Receiver drier
Receiver drier 80-21

Function 80-21
q The receiver drier temporarily stores the
high-pressure and high-temperature liquid refrig-
erant from the condenser so that it can be sup-
plied to the evaporator according to the need of
cooling.
q It sends the stored refrigerant from its bottom to
the evaporator, allowing the refrigerant to be liq-
uefied completely ever when it contains air bub-
bles due to the lowered heat dissipation of the
condenser.
q The built-in filter and desiccating agent eliminate
foreign substances in the circulation circuit and
water content in the refrigerant.
Effective volume (cc) 370
Weight of desiccating agent
290
(g)
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
WA1200-6 80-21
Air conditioner
Service tools
Service tools 80-2

1. Service tool kit
Measuring tools for testing operating pressure
– 799-703-1200 Service tool kit
q The service tool kit consists of a gauge man-
ifold and connecting hoses.
a Use the service tool kit designed for R134a to
measure the operating pressure of air condi-
tioner systems charged with R134a. Connec-
tion parts of the service tool kit for R134a
differ in diameters to prevent wrong connec-
tions.
1. Gauge manifold k *: Center hose (4), service can valve (7),

2. High-pressure hose (red) (inside diameter of and service can T-joint (8) are tools used
fitting: 12 mm) only for charging with refrigerant.
3. Low-pressure hose (blue) (inside diameter of Ask a qualified shop for collecting, add-
fitting: 10 mm) ing, and filling operation of refrigerant
4(*). Center hose (green) (inside diameter of (R134a). See "Precautions for refriger-
fitting: 10 mm) ant".
5. Quick joint (outside diameter of fitting: 12 mm)
6. Quick joint (outside diameter of fitting: 10 mm)
7 (*). Service can valve
8 (*). Service can T-joint
80-22 WA1200-6
Air conditioner
Service tools
2. Gauge manifold
q The gauge manifold is used for testing oper-
ating pressures of the refrigeration cycle.
1) Structure of gauge manifold

Dials on the front of the gauge manifold are
for opening and closing valves. Characters
LO and HI indicate the low-pressure valve
and high-pressure valve respectively. The
valves can be positively opened and closed
by turning the respective dials.
1. Gauge manifold 1-4. Low-pressure valve dial (LO)

1-1. Low-pressure gauge 1-5. High-pressure valve (HI)
1-2. High-pressure gauge 1-6. Low-pressure valve (LO)
1-3. High-pressure valve dial (HI) 1-7. Built-in air purge valve
WA1200-6 80-23
Air conditioner
Service tools
2) Handling of gauge manifold 4] When both low-pressure valve dial (LO)

By combining opening and closing of the and high-pressure valve dial (HI) are set
high- and low-pressure valve using the dials, to "Open"
following four different refrigerant circuits are
formed.
1] When both low-pressure valve dial (LO)
and high-pressure valve dial (HI) are set
to "Closed"
3) High-pressure, low-pressure, and center

hoses
The three hoses are color coded in red (2),
blue (3), and green (4). Connect them as
follows.
2] When low-pressure valve dial (LO) is set q Red (2): To high-pressure side of gauge
to "Open" and high-pressure valve dial manifold
(HI) is set to "Closed" q Blue (3): To low-pressure side of gauge
manifold
q Green (4): To center of gauge manifold
a When putting the gauge manifold into
storage, connect the hoses to the open
ports of the gauge manifold to prevent en-
try of foreign matter and moisture.
a Hose ends can be securely connected to
the mating part by finger-tightening only,
with the aid of the packing built in the
hose end nuts. They don't have to be
tightened with pliers or other tools.
k Center hose (4) is used only for charg-
ing with refrigerant. Ask a qualified
shop for collecting, adding, and filling
3] When low-pressure valve dial (LO) is set operation of refrigerant (R134a). See
to "Closed" and high-pressure valve dial "Precautions for refrigerant".
(HI) is set to "Open"
80-24 WA1200-6
Air conditioner
Service tools
4) Quick joints a It may be difficult to connect if refriger-

Quick joint (5) (with check valve) allows the ant remains in the hose. In this case,
connection of gauge manifold hose (2) and press part C to release the remaining
service valve (10) of the air conditioner piping pressure in the hose.
in a one-touch operation.
Two types of quick joints are provided. Quick
joint for high-pressure and quick joint for
low-pressure are distinguished as follows.
q Low-pressure quick joint: quick joint to be
connected to the low-pressure hose
(blue). Its inside diameter is 10 mm.
q High-pressure quick joint: quick joint to be
connected to the high-pressure hose
(red). Its inside diameter is 12 mm.
a In the following descriptions, connecting
procedures are explained using numbers
for the high-pressure hose . The proce-
dures are basically the same for the
low-pressure hose. 2] Disconnecting quick joints
While holding part A of quick joint (5),
slide part B of sleeve (9) upward.
a After disconnection, plug service
valve (10).
1] Connecting quick joints

Put quick joint (5) against service valve
(10) and press part A firmly until a click is
heard.
a When connecting the quick joint, take
care not to bend the pipe.
a If connection to service valve (10) has
failed and sleeve (9) has moved, reset
sleeve (9) to its original position and
try to connect the quick joint again.
WA1200-6 80-25
Air conditioner
Service tools
3. Connection of service tools 4) Connect quick joint (5) to service valve (10)
Connect service tools such as gauge manifold at the high-pressure side piping, and connect
(1) and hoses according to the following proce- quick joint (6) to service valve (11) at the
dure. low-pressure side piping.
1) Set high-pressure valve dial (HI) (1-3) and a For connecting procedures, see "2. 4)
low-pressure valve dial (LO) (1-4) of gauge Quick joints".
manifold (1) to "Closed". a Depending on the machine, the service
2) Connect red hose (2) to the HI side and the valves may be provided on compressor
blue hose (3) to the LO side of gauge mani- (12).
fold (1). a Be sure to use quick joints for connection
3) Connect quick joints (5) and (6) to hoses (2) of both high-pressure and low-pressure
and (3) respectively. hoses. If the quick joint is not used for
a Note that quick joints for low-pressure connection of one hose, air may leak in
and high-pressure have different outside and vacuum will not be maintained. (The
diameters at their fittings. check valve built in the quick joint cannot
High-pressure quick joint (5): outside hold vacuum.)
diameter of fitting 12 mm k Take care not to connect the hoses to
Low-pressure quick joint: outside diam- high-pressure and low pressure ports
eter of fitting 10 mm of the gauge manifold reversely.
80-26 WA1200-6
Air conditioner
Service tools
4. Gas leak detector

Tools for testing refrigerant gas leakage
Symbol Part No. Part name a The conventional halide torch leak tester
– 799-703-1401 Gas leak detector cannot detect R134a refrigerant, which does
not contain chlorine.
q This is an electric tester used for detecting re-
frigerant gas leaking from the refrigeration
cycle at connections, etc.
q Place the probe end to the place to check for
leakage, and slowly move the probe to find
the leaking point.
q The sound and light flashing becomes quick
when the probe comes close to the leaking
point.
q This gas leak detector can be used to detect
gas leakage of both R134a and conventional
R12.
1. Battery charger 5. Sensitivity selector switch

2. Internal battery 6. Suction probe
3. Sensor (under cover) 7. Check leak bottle
4. Speaker 8. Power switch
WA1200-6 80-27
Air conditioner
Service tools
5. Belt tension gauge

Measuring tool for belt tension
Symbol Part No. Part name Belt tension gauge (1) can be remote-controlled
–
Commercially
Belt tension gauge
by connecting remote cable (2), to facilitate work
available at inside the engine compartment where the
space is limited.
Incorrect belt tension adversely affects the life of
bearings and the belt itself.
Belt tension gauge (1) is a tool for measuring the
belt tension. Belt tension can be accurately and
easily measured with this tool. Be sure to use
this belt tension gauge especially when
adjusting V-belts.
80-28 WA1200-6
Air conditioner
Troubleshooting procedures
Troubleshooting procedures 80-29
q Air conditioner failures can be generally classi-

fied into two types; refrigeration cycle problems
and electrical problems. Troubleshooting by fol-
lowing the basic procedures are explained be-
low.
q The diagram shows the basic procedures of
troubleshooting.
(*): Basic checks

q Control mechanism
q V-belt
q Sight glass
q Piping connections
WA1200-6 80-29
Air conditioner
Interview and confirmation of failure symptom
Interview and confirmation of failure symptom 80-30
Before performing troubleshooting, the symptom

and occurring conditions of the problem must be
carefully checked. You should hear from the opera-
tor about the conditions when the problem occurs,
especially when it occurs sporadically or the symp-
tom cannot be reproduced at the workshop. "Inter-
viewing" is essential.
<Important interview questions>
q Which o Model, serial number
q When o Date, time, and frequency of occur-
rence
q Where o Condition of the work site
q Under what conditions o Working condition
and weather
q What happens o How you feel the symptom
80-30 WA1200-6
Air conditioner
Basic checks
Basic checks 80-31
1. Checking control mechanism

Operate the switches on control panel (1) to
check if they work smoothly and positively.
a Inspect fuses as necessary.
2. Checking V-belts
Check the V-belt tension and check for
damages.
3. Check the refrigerant volume through the
sight glass.
If lots of bubbles are seen through sight glass
(1), the refrigerant may be insufficient. Check it
by using the gauge manifold.
a For details, see "2. Checking of refrigerant
volume through sight glass".
4. Checking piping connections

If piping connections are oily, refrigerant may be
leaking out. Remove the smear and then check
for gas leaks.
WA1200-6 80-31
Air conditioner
Troubleshooting
Troubleshooting 80-32
1. Cooling trouble
1) Insufficient air flow
q Check the operation of blower motor
No. Details of problem Cause Remedy
q Clean recirculation air filter.
q Clogged recirculation air filter
q Clean fresh air filter.
q Clogged fresh air filter
q Remove obstacles.
q Obstacle at air intake
Blower motor rotates normal q Replace blower.
1 q Deformed or damaged blower
but air flow is insufficient. q Turn off air conditioner to let
q Frost on evaporator
the ice melt, and then go to
"Cause and remedy A".
q Dirt on evaporator
q Clean evaporator surface.
q Check battery charging sys-
q Dropped power supply voltage
tem.
Blower motor does not rotate q Defective contact at battery terminals
2 q Correct battery terminals.
normally. q Defective blower motor
q Replace blower motor.
q Defective blower Hi relay
q Replace blower Hi relay.
q Open circuit in resistor (rotates only in
Hi-speed setting) q Replace resistor.
q Blown fuse q Replace fuse, and then go to
"Cause and remedy B".
q Defective power maximizing relay on q Replace power maximizing
machine relay.
3 Blower motor does not rotate.
q Defective blower motor q Replace blower motor.
q Interference of blower with case q Correct interference.
q Defective blower switch q Replace panel.
q Defective chassis ground q Improve grounding.
q Defective wiring or disconnection of q Check wiring.
connectors
k When removing or replacing parts in the refrigeration cycle, collect refrigerant in advance.
Be sure to ask a qualified shop for collecting, adding, and filling operation of refrigerant
(R134a). For details, see "Precautions for refrigerant".
80-32 WA1200-6
Air conditioner
Troubleshooting
2) When the air flow is normal

q Check the operation of the compressor.

q Broken or slipping V-belt
q Replace V-belt
q Defective compressor
q Replace compressor
q Defective magnetic clutch
q Repair or replace magnet
1 Compressor does not run. clutch, or. go to "Cause and
remedy D-1".
q Clutch is not engaged due to defec-
q Check wiring, and the go to
tive electrical system.
"Cause and remedy D-2".
a Connect service tools to check if
2 Compressor runs normally. compressor pressure is normal, and –
then go to No. 3 or No. 4
q Close windows and doors, or
q Outside air leaking in cab
Compressor pressure is nor- adjust FRESH/RECIRC air
3
mal changeover damper.
q Airmix linkage disconnected
q Reset airmix linkage.
q Pressure of low-pressure circuit is
too high.
q Go to "Cause and remedy
(approx. 0.29 MPa {3 kg/cm2} or
C-2".
higher)
q Pressure of high-pressure circuit is
too low.
C-3".
(does not exceed approx. 0.98 MPa
4
Compressor pressure is {10 kg/cm2})
abnormal. q Pressure of low-pressure circuit is
too low.
C-4".
(drops below approx. 0.05 MPa
{0.5 kg/cm2}) q Go to "Cause and remedy
q Pressure of both high-pressure and C-5".
low-pressure circuits is too high. q Lack of refrigerant
q Pressure of both high-pressure and
low-pressure circuits is too low.
k When removing or replacing parts in the refrigeration cycle, collect refrigerant in advance.
Be sure to ask a qualified shop for collecting, adding, and filling operation of refrigerant
(R134a). For details, see "Precautions for refrigerant".
3) Abnormally high or low refrigerant pressure

Cut-off of high-pressure cir-
1 q Go to "Cause and remedy C-1". –
cuit
2 Cut-off of low-pressure circuit q Go to "Cause and remedy C-3". –
WA1200-6 80-33
Air conditioner
Troubleshooting
Cause and remedy
No. Cause Remedy
<Mixed defroster and face vent type> q Check magnet clutch circuit or
q Defective magnet clutch circuit replace relay.
q Check for short circuit and re-
q Defective frost sensor wiring pair.
q Defective frost sensor characteristics q Check sensor characteristics or
q Defective adjustment of gap between frost sensor replace sensor.
Voltage is applied and evaporator (poor sensitivity) q Adjusted gap: 12 ± 5 mm
to magnet clutch. (See Fig. 1)
A
<Independent defroster and face vents type> q Check magnet clutch circuit or
q Defective magnetic clutch circuit replace relay.
q Check for short circuit and re-
q Defective thermostat wiring pair.
q Malfunction of thermostat q Check thermostat operation or
replace thermostat.
Voltage is not
applied to magnet q Defective magnet clutch q Replace
clutch.
q Blower motor locked q Replace blower motor.
B – q Incorrect wiring q Repair
q Short circuit in wiring q Repair or replace
–
q Abnormally high outside air temperature
q Clean fins (wash fins with wa-
q Insufficient cooling at condenser
ter).
(fins clogged with dirt or mud)
1 q Filling too much with refrigerant
q Remove excessive refrigerant.
q Collect all refrigerant, evacuate
q Air in refrigerant cycle
the system, and then refill with
proper quantity of refrigerant.
q Filling too much with
refrigerant q Remove excessive refrigerant.
C
Damaged cylinder head
gasket
q Defective compres-
Breakage of inlet valve q Replace compressor.
2 sor
Foreign matter caught in
inlet valve
Defective valve q Replace
q Expansion valve
opening too wide Defective contact of tem-
q Repair
perature sensing bulb
k When removing or replacing parts in the Fig. 1
refrigeration cycle, collect refrigerant in
advance. Be sure to ask a qualified shop
for collecting, adding, and filling opera-
tion of refrigerant (R134a). For details, see
"Precautions for refrigerant".
80-34 WA1200-6
Air conditioner
Troubleshooting
No. Cause Remedy

–
q Abnormally low outside air temperature
q Refill with refrigerant to spec-
q Lack of refrigerant
ified level.
q Perform a leak test, repair
leaking point, and then refill
with refrigerant.
Swash plate shoe locked
q Defective compressor Piston locked q Replace compressor.

3
Defective inlet or outlet valve
Clogged valve q Replace valve.

Gas leak at temperature
q Replace valve.
q Defective expansion sensing bulb
valve q Replace valve and receiver,
Valve temporarily clogged
and then evacuate system
due to icing
thoroughly.
C –
q Abnormally low outside air temperature
q Refill with refrigerant to spec-
q Lack of refrigerant
ified level.
q Perform a leak test, repair
leaking point, and then refill
with refrigerant.
q Replace receiver drier.
q Clogging in refrigeration cycle
4 q Replace piping.
Clogged valve. q Replace valve.
Gas leak at temperature
q Replace valve.
q Defective expansion sensing bulb
valve Replace valve and receiver,
q
Valve temporarily clogged
and then evacuate system
due to icing
thoroughly.
q Frost on evaporator q (to troubleshooting No. A)
q Insufficient cooling at condenser q Clean clogged fins.
5 q Filling too much with refrigerant q Remove excessive refriger-
ant.
k When removing or replacing parts in the refrigeration cycle, collect refrigerant in advance. Be sure to
ask a qualified shop for collecting, adding, and filling operation of refrigerant (R134a). For details, see
"Precautions for refrigerant".
WA1200-6 80-35
Air conditioner
Troubleshooting
No. Cause Remedy

q Open circuit in stator coil q Replace
q Excessive air gap between rotor and stator q Repair or replace
Broken or missing key q Replace key.
Oily clutch surface q Remove oil.

1
q Slipping clutch
Layer short in coil q Replace
Dropped battery voltage q Charge

q Foreign matter caught between rotor and stator q Overhaul them.
q Defective air conditioner switch
D q Replace control panel.
q Defective blower switch
q Replace control panel.
q Defective compressor clutch relay
q Replace
q Defective thermosensor
q Replace
q Defective refrigerant pressure switch for high-pressure or
q Replace
low-pressure circuit
2 Abnormally high refrigerant q (Go to troubleshooting No.
pressure C-1.)
q Abnormally high refriger- (2.5 MPa {25 kg/cm2} or
ant pressure of high-pres- higher)
sure circuit Abnormally low refrigerant q (Go to troubleshooting No.
pressure C-4.)
(below 1.0 MPa {10 kg/cm2})
k When removing or replacing parts in the refrigeration cycle, collect refrigerant in advance. Be
sure to ask a qualified shop for collecting, adding, and filling operation of refrigerant (R134a).
For details, see "Precautions for refrigerant".
80-36 WA1200-6
Air conditioner
Troubleshooting
2. Heating trouble
a Be sure to check that the water pump is normal and IN/OUT heater hoses are not reversely connected.
1) Insufficient air flow
a See "1. Cooling trouble, 1) Insufficient air flow".
2) When the air flow is normal

q Bleed air from hot water cir-
q Air in hot water circuit cuit.
Engine coolant temperature
q Clogged or bent piping q Repair or replace
1 is normal but heating is
q Low engine coolant level q Add coolant to specified lev-
insufficient.
q Broken heater core el.
q Replace heater core.
q Abnormally low outside air tempera-
Low engine coolant temper- –
2 ture
ature q Close windows and doors.
q Outside air leaking in cab
q Temperature control linkage discon- q Reset temperature control
Temperature control LED is
3 nected linkage.
operating normally.
q Foreign matter caught in linkage q Remove foreign matter.
q Defective wiring, open circuit, defec-
Temperature control LED is q Check wiring.
4 tive contact of connector
not operating normally. q Replace servomotor.
q Defective servomotor
3) Water leakage into cab
1 Water leakage into cab Clogging of drain hole q Clean
4) Defective FRESH/RECIRC air changeover

FRESH/RECIRC servomo-
1 q Linkage disconnected q Reset linkage.
tor is normal.
q Defective wiring, open circuit, defec-

q Check wiring.
FRESH/RECIRC servomo- tive contact of connector
2 q Replace servomotor.
tor is abnormal. q Defective servomotor
q Remove foreign material.
q Foreign matter caught in
WA1200-6 80-37
Air conditioner
Checking of refrigeration cycle
Checking of refrigeration cycle 80-38

2) Lack of charged refrigerant
1. Measuring by using gauge manifold q Symptom
Use the gauge manifold to measure the refrig- 1] Pressure of both high-pressure and
erant pressure of high-pressure and low-pres- low-pressure sides is low.
sure sides of the refrigeration cycle under the 2] Continuous flow of bubbles can be seen
following conditions when performing trouble- through sight glass.
shooting. 3] Insufficient cooling
a Connect the gauge manifold. For details, see q Cause
"Service tools, 3. Connection of service tool". 1] Lach of refrigerant
<Conditions> 2] Leakage of gas
After performing warm-up operation of the q Points of remedy
engine, take measurements under the following 1] Checking for gas leakage and repairing
conditions. 2] Refill with refrigerant
q Doors: fully open
q FRESH/RECIRC air changeover: RECIRC
q Engine speed: 1,500 rpm
q Temperature at air conditioner suction port:
30 °C–35 °C
q Blower speed: HI
q Temperature control: max cool
a Reading on the gauge manifold may some-
what differ depending on the conditions.
1) When refrigeration cycle is normal

Under above conditions;
Pressure of low-pressure side:
0.15–0.25 MPa {15–25 kg/cm2}
Pressure of high-pressure side: 3) Excessive refrigerant and insufficient
1.37–1.57 MPa {14–16 kg/cm2} cooling at condenser
a Gauge in the drawing is calibrated in SI q Symptom
units, however, the actual gauge is cali- 1] Pressure of both high-pressure and
brated also in conventional units. low-pressure sides is high.
2] Bubbles cannot be seen through the sight
glass at low speeds
3] Insufficient cooling
q Cause
1] Excessive refrigerant
2] Failure in cooling condenser
q Points of remedy
1] Correct amount of refrigerant.
2] Clean condenser.
3] Check cooling system of machine (elec-
tric fan, etc.).
80-38 WA1200-6
Air conditioner
4) Water in refrigeration cycle 6) Refrigerant does not circulate (clogging

q Symptom in refrigeration cycle).
1] Low-pressure gauge gradually reads q Symptom
negative pressure after certain period of 1] If clogged completely, low-pressure
operation. gauge reads negative pressure immedi-
q Cause ately. If partially clogged, low-pressure
1] Entry of water gauge reads negative pressure gradually.
q Points of remedy 2] Temperatures across the clogged part
1] Replace receiver tank. are different.
2] Thoroughly evacuate system to remove q Cause
water before refilling with refrigerant. 1] Dirt or frozen water on holes in expansion
valve, etc. obstructs flow of refrigerant.
q Points of remedy
1] Replace receiver tank.
2] Thoroughly evacuate the system.
5) Defective compression at compressor

q Symptom
1] Pressure of low-pressure side is too high
and pressure of high-pressure side is too
low. 7) Air in refrigeration cycle
2] Pressure of high- and low-pressure sides q Symptom
become the same as soon as the air 1] Pressure of both high-pressure and
conditioner is turned off. low-pressure sides is high.
q Cause 2] Low-pressure side piping is not cold when
1] Defective compressor touched.
q Points of remedy 3] Bubble can be seen through the sight
1] Check and repair compressor. glass.
q Cause
1] Entry of air
q Points of remedy
1] Replace refrigerant.
2] Thoroughly evacuate the system.
WA1200-6 80-39
Air conditioner
8) Expansion valve opening too wide

q Symptom
1] Pressure of both high-pressure and
low-pressure sides is high.
2] Frost (dew) adheres to low-pressure
piping.
q Cause
1] Malfunction of expansion valve
q Points of remedy
1] Check installed condition of temperature
sensing bulb.
80-40 WA1200-6
Air conditioner
2. Troubleshooting chart
No. Symptom Location Condition Probable cause Remedy
Pressure of High- and
low-pressure sides
Defective compression at
Compressor become the same as Replace compressor.
compressor
soon as the compressor
turns off.
Pressure of both high- Defective valve or excessive
and low-pressure sides opening Replace expansion valve.
Pressure of is high, low-pressure (defective adjustment)
low-pressure side Expansion valve hose and service valve
1 is too high (above of low-pressure side are Defective contact of tempera-
Seizure of temperature sensing
approx. 0.3 MPa abnormally cold, and ture sensing bulb
bulb
2 frost (dew) adheres to (moved from installed position)
{3 kg/cm }).
piping.
Pressure of both high- Excessive refrigerant Correct amount of refrigerant.
and low-pressure sides Clean (wash with water),
Refrigeration is high, and pressure of check, or repair condenser fins.
cycle low-pressure side drops Defective cooling of con- Check and repair cooling sys-
when condenser is forc- denser tem of machine (electric fan,
ibly cooled. radiator, etc.).
Loose or broken fan belt Retighten or replace.
Defective fan motor or slipping
Replace motor or fix fan.
Condenser cooling fan fan
does not draw in Fan installed in wrong direc- Reinstall fan in correct direc-
Condenser
enough air (insufficient tion tion.
cooling air flow). Fan shroud missing Install correct shroud.
Condenser fins clogged with Clean (wash with water),
foreign matter check, or repair condenser fins.
Lack of coolant or oil Add to specified level.
Pressure of
Incorrect fuel injection timing Adjust to specification.
high-pressure side Engine tends to over-
2 is too high (above Engine heat. Defective water pump or poor
Repair or replace.
approx. 2 MPa capacity
{20 kg/cm2}). Radiator fins clogged with for-
Clean fins (wash with water).
eign matter
Bubbles cannot be
seen through the sight
Excessive refrigerant Correct amount of refrigerant
glass when condenser
Refrigeration is cooled with water
cycle Pressure drops approx.
0.2 MPa {2 kg/cm2} Air in refrigerant cycle
Change refrigerant (thoroughly
immediately after com- evacuate the system).
pressor turns off.
Abnormally high outside air
Others Excessive thermal load Enhance cooling of condenser.
temperature
Clogging of expansion valve
(defective adjustment, entry of Replace expansion valve.
foreign matter)
Expansion valve is not
Pressure of Gas leak at temperature sens-
wet with dew, and Replace expansion valve.
low-pressure side ing bulb
low-pressure piping is
Replace expansion valve,
3 is too low (below Expansion valve not cold. Expansion valve temporarily
receiver tank, and drier, and
approx. 0.05 MPa clogged due to icing (problem
then thoroughly evacuate the
{0.5 kg/cm2}). caused by water in circuit)
system.
Expansion valve frosted (defective adjustment, entry of Replace expansion valve.
foreign matter)
k When removing or replacing parts in the refrigeration cycle, collect refrigerant in advance. Be sure to ask a
qualified shop for collecting, adding, and filling operation of refrigerant (R134a). For details, see "Precautions
for refrigerant".
WA1200-6 80-41
Air conditioner
No. Symptom Location Condition Probable cause Remedy

Poor cooling, and con- Lack of refrigerant Add to specified level.
tinuous flow of bubbles
can be seen through Leakage of gas Check and repair gas leakage.
Refrigeration
Pressure of sight glass
cycle
low-pressure side Receiver tank and drier Clogging of receiver tank, or Replace receiver tank or drier
is too low (below is abnormally cold (ex. drier (thoroughly evacuate the sys-
3
approx. 0.05 MPa frosted). (Entry of foreign material) tem).
Output air temperature
{0.5 kg/cm2}). is low, and air is not Evaporator is frosted.
Check and adjust amplifier and
thermistor.
Others delivered.
Abnormally low outside air
Insufficient thermal load –
temperature
Pressure of high- and
low-pressure sides
Defective compression at
Compressor become the same as Replace compressor.
compressor
soon as compressor
turns off.
Pressure of (defective adjustment, entry of Replace expansion valve.
high-pressure side foreign matter)
Expansion valve is not
Gas leak at temperature sens-
4 is too low (below wet with dew, and Replace expansion valve.
Expansion valve ing bulb
approx. 1 MPa low-pressure piping is
Replace expansion valve,
{10 kg/cm2}). not cold. Expansion valve temporarily
receiver tank, and drier, and
clogged due to icing (problem
then thoroughly evacuate the
caused by water in circuit)
system.
Poor cooling, and con-
Refrigeration tinuous flow of bubbles
Lack of refrigerant Add to specified level.
cycle can be seen through
sight glass.
Shaft seals are oily and
Compressor Gas leakage from shaft seals Replace compressor.
gas level goes down.
Leakage of gas or
5 Piping joints are oily
oil Refrigeration Gas leakage from piping con- Retighten piping connection or
and gas level goes
cycle nection replace piping.
down.
Open circuit in coil Replace
Magnet clutch does not Wire breakage, defective wir-
engage even when air ing, or defective connection of Connect, repair, or replace
conditioner switch is wiring parts (grounding, fuses, parts that have open circuits.
ON.. etc.)
Magnet clutch does Defective contact or malfunc-
6 Clutch body Repair or replace.
not engage. tion of switch
Magnet clutch engages
if pressing it so that
Excessive gap between rotor
rotor moves slightly as Repair or replace.
and stator
soon as air conditioner
switch is turned to ON.
Dropped battery voltage Charge battery.
Slipping magnet Clutch slips during rota-
7 Clutch body Clutch surface is dirty with oil. Remove oil.
clutch tion.
Layer short in coil Replace
k When removing or replacing parts in the refrigeration cycle, collect refrigerant in advance. Be
sure to ask a qualified shop for collecting, adding, and filling operation of refrigerant (R134a).
For details, see "Precautions for refrigerant".
80-42 WA1200-6
Air conditioner
3. Check of gas leakage

If a refrigerant leakage is suspected during basic
checks, inspect the system using gas leak
detector (1) according to the following proce-
dure.
k Do not use a halide torch leak tester

for checking gas leakage.
This type of tester detects gas leakage
by sensing chlorine. It should never be
1. Gas leak detector used, not only because R134a does
2. Suction probe not contain chlorine, but also it will de-
compose R134a into harmful sub-
1) Performing preliminary check stances.
Connect the gauge manifold and check the
condition of refrigerant remaining in the
refrigeration cycle.
Then, add refrigerant as necessary to
increase the pressure in the refrigeration
cycle to facilitate the gas leakage check. This
is the purpose of the preliminary check.
a For the connection of the gauge mani-
fold, see "Service tools, 3. Connection of
service tool".
1] Read the gauge when the compressor is
not running.
a Ambient temperature must be 15 °C
or higher.
2] If the gauge reading is above approx. 0.4
MPa {4 kg/cm2}, proceed with the check.
3] If the gauge reading is below approx. 0.4
MPa {4 kg/cm2}, add refrigerant until the
pressure becomes approx. 0.4 MPa
{4 kg/cm2} or higher, and then proceed
with the check.
a Check for leakage of gas in a well venti-
lated area.
Electrical gas leak detectors may give a
false diagnosis if it detects gasoline or
diesel fuel vapor, or exhaust gas in the
sensor portion.
a Note that gas leaking from a piping con-
nection can be carried away by a slight
movement or air. When bringing the end
of suction probe (2) close to the suspect-
ed area, check in all directions from the
area.
WA1200-6 80-43
Air conditioner
2) Checking procedure of gas leakage
80-44 WA1200-6
Air conditioner
[Reference] ?Pressurizing with air)

q Checking gas leakage by pressurizing 1] Connect the air compressor by using
with air gauge manifold (3), air attachment (1),
This checking procedure can be applied to and plug (2).
facilitate the leakage check by pressurizing
the refrigeration cycle with nitrogen gas or air
when the refrigerant level in the cycle is low.
1] Necessary tools
(1) Air attachments:
Dedicated attachment for connecting
the gauge manifold
(2) Plug:
A plug for connecting to the shop air
piping. (Choose a suitable plug from
commercially available products.)
2] Checking method
a. Read the gauge when the compressor
is not running.
a Ambient temperature must be 15 °C 2] Start the air compressor and send air to
or higher. the air conditioner piping to pressurize the
q If the gauge reading is approx. 0.2 to
refrigeration cycle.
0.4 MPa {2 to 4 kg/cm2}, proceed with a Air pressure: 1.0 MPa {10 kg/cm2}
the check. 3] After the refrigeration cycle is pressur-
q If the gauge reading is below approx.
ized, set the valve dial on the gauge mani-
0.2 MPa {2 kg/cm2}, add refrigerant fold to "Closed" in order to maintain
until the pressure becomes approx. pressure in the air conditioner piping.
0.4 MPa {{4 kg/cm2} or higher, and a Be sure to drain water from the air com-
then proceed with the check. pressor used for pressurizing. Water will
b. Check for gas leaks by using a gas hardly enter the refrigeration cycle if this
leak detector. work is performed.
a When the gas leakage check is com- a Limit the charging air pressure to 1.0 MPa
plete, replace the refrigerant with new {10 kg/cm2} or below.
refrigerant if air is mixed in the gas. k Ask a qualified shop for collecting,
adding, and filling operation of refrig-
erant (R134a). For details, see "Pre-
cautions for refrigerant".
WA1200-6 80-45
Air conditioner
Troubleshooting for unusual noise
Troubleshooting for unusual noise 80-46
1. Unusual noise may be generated in various 2. General causes and sources of unusual noise
operating conditions, so ask the following ques- are shown below.
tions for troubleshooting.
q Is the unusual noise heard when the air con-
ditioner is off?
q Is the unusual noise heard only when the air
conditioner is on?
q Is the unusual noise heard sometimes, con-
tinuously, or immediately after the air condi-
tioner is turned on?
To locate the source of unusual noise, it is
necessary to perform checks carefully taking
into account the information obtained from the
interview .
Sources of unusual noise Cause
V-belt q Looseness
q Worn or broken bearing
Magnetic clutch
q Interference between stator and rotor
q Foreign material caught in
Blower motor
q Insufficient tightening of blower
Unusual noise q Loosened bracket mounting bolt
q Defects related to valves
Compressor
q Worn or broken bearing
q Misalignment
q Poorly tightened or improperly installed clamps and fas-
Piping teners
q Improper safety gaps
[Reference]
q Checking sources of unusual noise 2] Place stethoscope (1) on compressor (2)
Using stethoscope (1) is one of the recom- and listen to check whether the same
mended methods to locate the source of unusual noise is heard from the inside. If the same
noise. noise is heard, compressor (2) may be
<Example> defective.
For example, unusual noise from compressor (2) a Generally, unusual noise from the com-
can be located as follows. pressor can be heard regardless of the
q If the noise is heard from around compressor engine speed.
(2), it is necessary to determine whether the
noise is generated from loose bracket mount-
ing bolts, pulley (4) sharing belts (3) with
compressor (2), or inside the compressor.
1] Place stethoscope (1) on pulley (4) to find
the source of noise.
80-46 WA1200-6
Air conditioner
Electrical system
1. Checking electrical system

See the electrical circuit diagram to gain an
understanding of the electrical circuit.
Then, check the connection of the electrical
components systematically by using a circuit
tester or the like.
General check points are shown below.
1) Blown fuse
1] Check the circuit protected by the blown
fuse by referring to the electrical circuit
diagram.
2] To check for a short circuit in each
component, disconnect the connector for
the part and check the component.
2) Defective contact of connectors
1] Note that a functional component may not
operate if there is a defective contact
between male and female connectors.
2] Contact in the connector may be defec-
tive if the functional component operates
unstably or malfunctions when the
machine vibrates.
3) Defective chassis ground
q Grounding points may be insulated by
paint, rust, etc. even if they appear to be
normal.
WA1200-6 80-47
Air conditioner
Electrical system
2. Electrical circuit diagram
80-48 WA1200-6
Air conditioner
Parts replacement
Parts replacement 80-49
1. Precautions for disconnecting refrigerant 3. Connection of piping

cycle piping 1) Precautions for connection
k Collect the refrigerant (air conditioner q When removing O-rings, use a soft tool to
gas: R134a) from air conditioner circuit avoid damaging the piping.
before disconnecting air conditioner pip- q When the piping or cycle parts were re-
ing to remove or replace the air condition- placed, be sure to replace the O-rings
er unit, air conditioner compressor, or with new ones for R134a.
receiver drier and so on. q When connecting the piping, apply com-
a Ask a qualified shop for collecting, adding, pressor oil (ND-OIL8) to O-rings and
and filling operation of refrigerant (R134a). tighten to the specified torque.
a Never release the refrigerant (R134a) to the a Do not apply oil to the threaded por-
atmosphere. tion of a bolt, nut, or union.
k If refrigerant gas (R134a) gets in your a Do not use mineral lubrication oils
eyes, you may lose your sight. According- such as SUNISO, CRC, etc.
ly, put on protective eyeglasses, safety
gloves and long sleeved work clothes
when collecting or charging with the re-
frigerant.
q Refill capacity of refrigerant (R134a):
1,400 ± 100 g
2. Interchangeability of air conditioner parts
q The components of the refrigeration cycle,
their closely related parts, and compressor
lubrication oil for R134a air conditioner sys-
tems are not interchangeable with those for
R12 air conditioner systems.
q To avoid wrong connection of parts, the joints
of each parts are made in different diame-
q Use two wrenches for secure connection.
ters. Since parts such as compressor oils and
a Hold the device side with one wrench
O-rings cannot be easily distinguished by the
and turn the flare nut of the hose with
appearance, strictly classify the parts into
another wrench.
R134a system parts and R12 system parts
for storage and use.
WA1200-6 80-49
Air conditioner
Parts replacement
2) Tightening torque of piping connection

Hose size Tube Thread size Tightening torque
Connection Used at
size (width across flats) (mm) (Nm {kgcm})
COND1 OUT
M16x1.5 12–15
f8 COND2 OUT A
(19) {118–147}
REC TO UNIT IN
Nut type M22x1.5 20–25 COND1 IN
D1/2 B
(24) {196–245} COND2 IN
M24x1.5 30–35
D5/8 UNIT OUT C
(27) {294–343}
Receiver tank portion 4.0–7.0
RECEIVER TANK –
M6x1.0 {39–69}
Block joint
Other than receiver tank 8.0–12.0 COMPRESSOR
–
M6x1.0 {78–118} A/C UNIT
1. Compressor
2. Condenser unit
3. Receiver drier
4. Air conditioner unit
80-50 WA1200-6
Air conditioner
Parts replacement
4. Refilling of compressor oil

1) When replacing functional components
When replacing functional components (such
as condenser, evaporator, etc.), refill with
following amount of new compressor oil .
a Add compressor oil for R134a. 40 cc oil
cans are available for refill purposes.
<Refill capacity of compressor oil>

Replacement parts
Compressor Condenser Evaporator Receiver tank Piping
Refill capacity of compressor 10 cc
80 cc 40 cc 40 cc 10 cc
oil (reference) (per container)
Compressor oil ND-OIL8
2) When replacing compressor

New compressor contains oil enough for the
refrigeration cycle. Therefore, when
replacing the compressor, it is necessary to
remove surplus oil from the new compressor.
1. Compressor to be replaced
2. New compressor
*: Remove surplus oil (A - B).
a Since compressor oil for R134a can easi-
ly absorb water, shut the container imme-
diately after use.
WA1200-6 80-51
Air conditioner
Periodic inspection and maintenance
Periodic inspection and maintenance 80-52
1. Inspection and maintenance items

Appropriate inspection and maintenance are required to keep the air conditioner at the best condition.
Generally, following inspection and maintenance are performed on air conditioner systems.
Inspection and maintenance interval
Inspection and maintenance items
Every six months Every 12 months
Refrigerant (gas) (sight glass) Refill capacity q q
Condenser Clogged fins q q
Compressor Operating condition q
Air filter (for FRESH/RECIRC q(Every three
Clogging
air) months)
Belt Damage and tension q q
Blower motor Operating condition and unusual noise q
Control mechanism Operating condition q
Installation condition, looseness at tighten-
Mounts and piping ing or connecting portions, leakage of gas, q q
and damage
a Replace the receiver drier and blower motor once in every four years.
1) Cleaning condenser
k Do not use a steam cleaner, since it
can heat the condenser causing a dan-
ger.
k When using pressured water, put on
protective glasses, dust mask, and
other protective gears since dirt will
scatter and it can cause injury.
q Remove cover (1) from the air conditioner
condenser.
q If mud or dirt is adhering to condensers
(2) and (3), wash off with water.
a If the water pressure is too high, the fins
may be deformed. Spray from an ade-
quate distance when using pressured wa-
ter.
a For details, see Operation and Mainte-
nance Manual, "Inspection and mainte-
nance, when required".
80-52 WA1200-6
Air conditioner
2) Cleaning air conditioner fresh air filter 3) Cleaning air conditioner recirculation air
element filter element
k When using compressed air, put on 1] Open filter inspection covers (1) and (2),
protective glasses, dust mask and oth- and remove filter cover (3).
er protective gears since dirt will scat- 2] Pull out filter (4) in the direction of the
ter and it can cause injury. arrow.
q Turn off the air conditioner before clean- a To pull out the lateral filter, put your
ing the element. weight on the seat to press down.
1] Open air conditioner fresh air filter cover 3] Clean the filter by using compressed air in
(1) at the rear of the cab. the same way as cleaning the fresh air
2] Remove wing bolt (2), and then remove filter. For details, see "Cleaning of air
and clean filter element (3). conditioner fresh air cleaner".
3] Blow dry compressed air (Max. 0.2 MPa a If the filter is severely contaminated,
{2 kg/cm2}) along the inside pleats of the rinse it with water. Dry the rinsed filter
element. thoroughly before reinstalling it.
Next, blow air along the outside pleats, a For details, see Operation and Mainte-
and blow again along the inside pleats. nance Manual, "Inspection and mainte-
a When reinstalling the outer element, in- nance, every 250 hours".
stall it with the arrow on the top of the el-
ement facing the inside of the cab.
a For details, see Operation and Mainte-
nance Manual, "Inspection and mainte-
nance, every 100 hours".
WA1200-6 80-53
Air conditioner
2. Checking of refrigerant volume (through 3. Checking of functional parts

sight glass) 1) Checking the control mechanism
1) Satisfy the following conditions. Operate the switches on control panel (1) to
q Door: fully opened check if they work smoothly and positively.
q Temperature control: max cool If any abnormality is found, check, adjust, or
q Blower speed: HI repair the abnormal part.
q FRESH/RECIRC air changeover: RE-
CIRC
q Engine speed: 1,500 rpm
q Air conditioner: ON
2) Check the condition of the refrigerant
through the sight glass.
<Criterion>
q Proper amount: Almost no bubbles are
seen.
: As the engine speed is
increased gradually from idle
speed to 1,500 rpm, bubbles
will decrease and the flow
becomes clear.
q Excessive refrigerant: No bubbles are
2) Checking belts
seen.
Check belt (1) for damage. If damaged,
: Pressure of both high- and
replace it with a new one.
low-pressure sides is high.
Also, check if the belt tension is within the
Cooling will be insufficient.
standard value range. If out of the standard
q Insufficient refrigerant: Continuous flow of
value range, adjust the belt tension.
bubbles can be seen.
a For details, see "Testing and adjusting
compressor belt tension".
80-54 WA1200-6
Air conditioner
3) Checking of compressor and magnet clutch 5) Cleaning condenser

Turn on the air conditioner switch to check if If a large amount of mud or dirt adheres to
magnet clutch (1) engages. fins of condenser (1), cooling will be insuffi-
Also, check if any unusual noise is heard cient. Wash them off with water.
from magnet clutch (1) or the compressor. a If heavily adhered, use a soft hair brush
If unusual noise is heard, adjust or repair the for washing.
component.
6) Checking of installation
4) Checking idler pulley Check the installed condition of each part
Check if any unusual noise is heard from idler (loosening of mounting bolts, nuts, screws).
pulley (1). If any part is loosened, retighten it.
If unusual noise is heard, repair the pulley.
7) Checking piping connection
Check if piping connection (A) is oily. If
smeared with oil, a refrigerant leakage is
suspected. Check for a gas leakage using a
gas leak detector.
If a gas leakage is found, repair or replace
parts.
a For details, see "Checking of refrigeration
cycle, 3. Checking for gas leakage".
WA1200-6 80-55
Air conditioner
Testing and adjusting compressor belt tension
Testing and adjusting compressor belt tension 80-56
Checking 80-56
a Check belt (1) for damage. If damaged, replace
it with a new one.
Adjust 80-56
a Press the middle point between compressor pul-
ley (2) and drive pulley (3) with a finger and
make adjustment so that deflection of belt (1) be-
comes (a).
q Deflection when pressed with force of ap-
proximately 98.1 N {10 kg}
(a): 9.0–12.5 mm
80-56 WA1200-6
SEN0547533-00 90-1
WA1200-6
WHEEL LOADER
Shop Manual 9-01
WA1200-6

WA1200-6 60001 and up
90 Diagrams and drawings 90-1
WA1200-6 90-1
Contents
Contents 90-2
90 Diagrams and drawings
Hydraulic circuit diagram......................................................................................................... 90- 3
Circuit symbols used in hydraulic circuit diagrams .............................................................. 90- 3
Transmission hydraulic circuit diagram................................................................................ 90- 6
Brake hydraulic circuit diagram............................................................................................ 90- 8
Work equipment hydraulic circuit diagram ........................................................................... 90- 11
Electrical circuit diagram ......................................................................................................... 90- 15
Circuit symbols used in electrical circuit diagrams............................................................... 90- 15
Electrical circuit diagram ...................................................................................................... 90- 19
90-2 WA1200-6
Hydraulic circuit diagram
Circuit symbols used in hydraulic circuit diagrams
Hydraulic circuit diagram 90-3

Circuit symbols used in hydraulic circuit diagrams 90-3
(Rev. 2010/03)
WA1200-6 90-3
90-4 WA1200-6
WA1200-6 90-5
Transmission hydraulic circuit diagram
Transmission hydraulic circuit diagram 90-6
90-6 WA1200-6
Transmission hydraulic circuit diagram
1. Transmission case
2. Strainer
3. Transmission, torque converter charging pump (SAR(4)200)
4. Torque converter charging pump (SAR(4)200)
5. Oil filter
6. Main relief valve
7. Torque converter relief valve
8. Torque converter
9. Torque converter regulator valve
10. Oil cooler
11. Lubricating oil relief valve
12. Transmission lubrication
13. Transfer lubrication
14. PTO, input transfer lubrication
15. Modulation clutch lubrication
16. Pilot oil filter
17. No.1 (reverse) clutch ECMV
18. No.1 (reverse) clutch bypass fill valve, bypass drain valve
19. No.1 (reverse) clutch
20. Transmission control valve oil temperature sensor
21. No.1 (forward) clutch ECMV
22. No.2 (forward) clutch bypass fill valve
23. No.2 (forward) clutch
24. No.3 (3rd) clutch ECMV
25. No.3 (3rd) clutch
26. No.4 (2nd) clutch ECMV
27. No.4 (2nd) clutch
28. No.5 (1st) clutch ECMV
29. No.5 (1st) clutch bypass fill valve
30. No.5 (1st) clutch
31. Modulation clutch ECMV
32. Modulation clutch
33. Parking brake circuit check valve
34. Parking brake solenoid valve
35. Parking brake emergency release valve
36. Parking brake (built-in transmission)
37. Accumulator (for brake)
A. From brake circuit
WA1200-6 90-7
Brake hydraulic circuit diagram
Brake hydraulic circuit diagram 90-8
90-8 WA1200-6
WA1200-6 90-9
1. Engine
2. Torque converter pump, transmission pump, brake cooling pump, brake pump
2A. Torque converter pump
2B. Transmission pump
2C. Brake cooling pump
2D. Brake pump
3. Strainer
4. Accumulator charge valve
5. Check valve
6. Accumulator
7. Low pressure sensor (for VHMS data)
8. Low pressure sensor (for caution)
9. Rear brake accumulator
10. Front brake accumulator
11. Emergency brake switch (for emergency parking brake cut-off solenoid)
12. Brake valve (left)
13. Transmission cut-off switch
14. Brake valve (right)
15. Stop lamp switch
16. Rear slack adjuster
17. Rear brake cylinder
18. Front slack adjuster
19. Front brake cylinder
20. Emergency parking brake valve
20A. Emergency parking brake cut-off solenoid
21. Emergency parking brake cut-off switch
22. Parking brake solenoid
23. Parking brake switch
24. Transmission (See transmission hydraulic circuit diagram.)
24A. Parking brake (built-in transmission)
25. Parking brake pilot lamp switch
26. Brake oil tank
27. Breather
28. Brake oil level switch
Brake cooling system circuit

29. Check valve
30. Brake oil temperature sensor
31. Brake oil cooler
32. Rear brake cooling
33. Front brake cooling
A. From transmission main circuit

E. To drain circuit
90-10 WA1200-6
Work equipment hydraulic circuit diagram (1/2) Work equipment hydraulic circuit diagram (1/2) 1
WA1200-6
WA1200-6
WA1200-6
90-11
Work equipment hydraulic circuit diagram (2/2) Work equipment hydraulic circuit diagram (2/2) 1
WA1200-6
WA1200-6
WA1200-6
90-13
Electrical circuit diagram
Circuit symbols used in electrical circuit diagrams
Electrical circuit diagram 90-15

Circuit symbols used in electrical circuit diagrams 90-15
(Rev. 2010/03)
WA1200-6 90-15
90-16 WA1200-6
WA1200-6 90-17
90-18 WA1200-6
Electrical circuit diagram (1/13) Electrical circuit diagram (1/13) 1
WA1200-6 WA1200-6
WA1200-6
90-19
WA1200-6
WA1200-6
WA1200-6
90-21
WA1200-6
WA1200-6
WA1200-6
90-23
WA1200-6
WA1200-6
WA1200-6
90-25
WA1200-6
WA1200-6
WA1200-6
90-27
WA1200-6
WA1200-6
WA1200-6
90-29
WA1200-6
WA1200-6
WA1200-6
90-31
WA1200-6
WA1200-6
WA1200-6
90-33
WA1200-6
WA1200-6
WA1200-6
90-35
WA1200-6
WA1200-6
WA1200-6
90-37
WA1200-6
WA1200-6
WA1200-6
90-39
WA1200-6
WA1200-6
WA1200-6
90-41
WA1200-6
WA1200-6
WA1200-6
90-43
Index
Index
A D
Accumulator (for brake) 10-119 Damper 10-4, 60-7
Accumulator (for EPC valve) 10-180 Differential 60-32
Adjusting AJSS lever angle sensor and frame angle Disassembly and assembly of center support 50-253
sensor 30-133 Disassembly and assembly of damper 50-91
Adjusting lift arm levelness detecting switch 30-130 Disassembly and assembly of differential 50-225
Adjusting lift arm potentiometer 30-129 Disassembly and assembly of drive shaft 50-203
Adjusting speed sensor 30-24 Disassembly and assembly of final drive and brake
Adjusting steering follow-up linkage 30-45 50-238
Adjustment method of auto grease injector delivery Disassembly and assembly of MESABI oil cooler 50-105
30-125 Disassembly and assembly of modulation clutch 50-142
Air conditioner components 80-12 Disassembly and assembly of operator seat 50-406
AJSS 10-68 Disassembly and assembly of parking brake 50-194
Axle 10-61 Disassembly and assembly of PTO and transfer 50-146
Axle mount 10-129, 60-54 Disassembly and assembly of torque converter 50-131
Disassembly and assembly of transfer 50-187
B Disassembly and assembly of transmission assembly
Basic checks 80-32 50-166
Basic precautions for KOMTRAX Plus controller 30-138 Disassembly and assembly of work equipment cylinder
Before performing troubleshooting of steering oil pressure 50-329
system (how to use the multi monitor) 40-595 Disassembly and assembly procedures for MESABI oil
Before performing troubleshooting of work equipment cooler 50-102
hydraulic system (how to use the multi monitor) 40-518 Disconnection and connection of torque converter
Bleeding air from brake circuit 50-66 assembly, PTO and transfer assembly 50-127
Bleeding air from hydraulic circuit 30-117 Disconnection and connection of transmission assembly
Bleeding air from piston pump 50-68 and torque converter assembly 50-120
Bleeding air from steering circuit 30-42 Disconnection and connection of transmission assembly,
Bleeding air from work equipment circuit and steering transfer, and parking brake assembly 50-159
circuit 50-69 Diverter valve 10-103, 60-43
Brake 10-122, 60-51
Brake equipment layout drawing 10-108 E
Brake hydraulic circuit diagram 90-8 E-1 Remote positioner "RAISE" or "LOWER" LED does
Brake oil pressure group 40-651 not light up 40-499
Brake oil pressure system, general 40-650 E-2 Open circuit or ground fault in check lamp system
Brake valve 10-109, 60-48 40-500
Breakage of hydraulic cylinder 40-24 E-3 Machine monitor does not operate 40-501
Bucket positioner, remote positioner 60-74 E-4 Turn signal lamp does not light up 40-502
E-5 Defective parking lamp 40-504
C E-6 Defective front working lamp 40-506
Center hinge pin 10-131, 60-56 E-7 Defective rear working lamp 40-508
Center support 10-60, 60-30 E-8 Headlamp does not light up 40-510
Charge valve 10-115 E-9 Service meter does not work, or service meter works
Check before troubleshooting 40-10 while engine is stopped. 40-512
Check valve of parking brake circuit 10-126 E-10 Monitor panel controller does not sound buzzer
Checking center hinge pin lubrication 30-123 40-514
Checking of refrigeration cycle 80-39 E-11 Defective auto-greasing system 40-516
Checking proximity switch operation pilot lamp 30-132 ECMV 10-29, 60-17
Checking steering related standard values 40-608 Electric fan and condenser 80-20
Circuit symbols used in electrical circuit diagrams 90-15 Electric parking brake control 10-347
Circuit symbols used in hydraulic circuit diagrams 90-3 Electrical circuit diagram 90-19
Classification and procedures of troubleshooting 40-21 Electrical system 80-48
Coating materials list 50-6 Emergency parking brake release valve 10-125
Compressor 80-19 Emergency steering pump 60-47
Configuration and function of refrigeration cycle 80-4 Emergency steering relief valve 10-106
Connector list and layout 40-84 Engine mount 60-3
Control system 80-8 Engine starting circuit 10-341
Conversion table 00-54 Engine stopping circuit 10-343
Cooling fan motor 10-6 EPC valve (for steering) 10-102
Cooling fan motor 60-5 EPC valve (for work equipment) 10-175
Cooling system 10-5, 60-4 equipment is low) 30-107
WA1200-6 1
Index
Explanation of terms for maintenance standard 00-23 Failure code [b@C5ZK] Low brake fluid level (before
engine start) 40-168
F Failure code [B@C5ZK] Low brake fluid level (while
Failure code [1500L0] Double Engagement of engine is running) 40-169
Transmission Clutches 40-110 Failure code [B@C6NS] High brake oil temp. 40-170
Failure code [1540N1] T/M overrun 40-111 Failure code [b@CENS] High torque converter oil temp.
Failure code [15B0NX] T/M Oil Filter Clogged 40-112 40-171
Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit Failure code [B@CENS] Very high torque converter oil
40-114 temp. 40-172
Failure code [15SALH] ECMV (F) Fill Switch circuit Failure code [B@GAZK] Low battery 1 fluid level 40-174
Disconnect 40-116 Failure code [B@GBZK] Low battery 2 fluid level 40-176
Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit Failure code [B@GCZK] Low battery 3 fluid level 40-178
40-118 Failure code [B@HANS] High hydraulic oil temp. 40-180
Failure code [15SBLH] ECMV (R) Fill Switch circuit Failure code [B@HAZK] Low hydraulic oil level 40-181
Disconnect 40-120 Failure code [D191KA] Neutral Output Relay
Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit Disconnection 40-182
40-122 Failure code [D191KB] Neutral Output Relay hot short
Failure code [15SELH] ECMV (1) Fill Switch circuit 40-184
Disconnect 40-124 Failure code [D19MKA] SW pump PNC solenoid Relay
Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit (Disconnect/Short Circuit) 40-186
40-126 Failure code [D19MKY] SW pump PNC solenoid Relay
Failure code [15SFLH] ECMV (2) Fill Switch circuit hot short 40-188
Disconnect 40-128 Failure code [D19MMA] SW pump PNC solenoid circuit 1
Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit Failure 40-190
40-130 Failure code [D19MMB] SW pump PNC solenoid circuit 2
Failure code [15SGLH] ECMV (3) Fill Switch circuit Failure 40-192
Disconnect 40-132 Failure code [D5ZHKA] Starting Switch C signal circuit
Failure code [2F00MA] Parking brake circuit failure (Disconnect/Short Circuit) 40-194
40-135 Failure code [D5ZHKB] Starting Switch C signal circuit
Failure code [2G42ZG] Accumulator Oil Press. F Low Hot short 40-196
40-138 Failure code [D5ZHKZ] Starting Switch C signal circuit
Failure code [2G43ZG] Accumulator Oil Press. R Low failure 40-198
40-140 Failure code [D5ZHL6] Ignition C terminal Circuit Failure
Failure code [44K0L4] Bucket cylinder position detector 40-200
SW failure 40-142 Failure code [DAF5KP] Monitor Panel 5 V source sys
Failure code [7REAKA] ACC Signal Malfunction 40-143 Error 40-202
Failure code [989P00] Direction protection warning Failure code [DAFRKR] Communication Lost Monitor
40-144 Panel Controller 40-204
Failure code [989Q00] Work equipment protection Failure code [DAQ0KK] Drop in Transmission Controller
40-144 Main Power Source 40-206
Failure code [989R00] Tire slip 40-145 Failure code [DAQ0KT] Nonvolatile Memory (EEPROM)
Failure code [989S00] Parking Brake Dragging 40-146 Abnormal 40-208
Failure code [989T00] Stationary steering (Brake: OFF, Failure code [DAQ2KK] Drop in Transmission Controller
Load: OFF) 40-148 Solenoid Power Source 40-210
Failure code [989U00] Stationary steering (Brake: OFF, Failure code [DAQRKR] Communication Lost T/M
Load: ON) 40-149 Controller 40-212
Failure code [989V00] Stationary steering (Brake: ON, Failure code [DAQRMA] Defective Option Selection Data
Load: OFF) 40-150 in Transmission 40-214
Failure code [989W00] Stationary steering (Brake: ON, Failure code [DB2RKR] Communication Lost Engine
Load: ON) 40-151 Controller 40-216
Failure code [AA1ANX] Air Cleaner 1 Clogging 40-152 Failure code [DB90KK] Drop in Work Controller Main
Failure code [AA1BNX] Air Cleaner 2 Clogging 40-154 Power Source 40-218
Failure code [AA1CNX] Air Cleaner 3 Clogging 40-156 Failure code [DB90KT] Nonvolatile Memory (EEPROM)
Failure code [AA1DNX] Air Cleaner 4 Clogging 40-158 Abnormal 40-220
Failure code [AB00L6] Discharge of alternator R terminal Failure code [DB92KK] Solenoid Voltage Failure (Work
40-160 controller) 40-222
Failure code [AB00MA] Discharge of alternator R terminal Failure code [DB95KX] 5 V source sys Error (Work
40-162 controller) 40-224
Failure code [AB00MB] Discharge of alternator R terminal Failure code [DB9RKR] Communication Lost Boom
40-164 Bucket & Joy stick Controller 40-226
Failure code [B@BCZK] Drop in Engine Coolant Level Failure code [DB9RMA] Defective Option Selection Data
40-166 in Boom Bucket Controller 40-228
2 WA1200-6
Index
Failure code [DB9RMC] Communication Lost (Work Failure code [DGH2KX] Hydraulic oil temp. sensor circuit
Controller) 40-230 failure 40-292
Failure code [DBB0KK] VHMS source voltage Error Failure code [DGR2KA] Brake oil temp. sensor circuit
40-232 Disconnection 40-294
Failure code [DBB0KQ] VHMS Connector Mismatch Failure code [DGR2KX] Brake oil temp. sensor circuit
40-234 failure 40-296
Failure code [DBB3KK] Abnormality in VBAT voltage Failure code [DGT1KX] T/C oil temp. sensor circuit failure
(VHMS VBAT<10V) 40-236 40-298
Failure code [DBB5KP] VHMS 5 V source sys Error Failure code [DH20KX] Torque converter pressure sensor
40-238 circuit 40-300
Failure code [DBB6KP] VHMS 24 V source sys Error Failure code [DH21KA] Loader pump oil press sensor
40-240 (Disconnect/Short Circuit) 40-302
Failure code [DBB7KP] VHMS 12 V source sys Error Failure code [DH21KB] Loader pump oil press sensor hot
40-242 short 40-304
Failure code [DBBQMC] Communication Lost (VHMS Failure code [DHPCKA] Boom bottom press.
CAN0) 40-243 (Disconnect/Short Circuit) 40-306
Failure code [DBBRKR] Communication Lost VHMS Failure code [DHPCKX] Boom bottom press. sensor
Controller 40-245 circuit failure 40-308
Failure code [DBBRMC] Communication Lost (VHMS Failure code [DHPCKY] Boom bottom press. hot short
CAN1) 40-246 40-310
Failure code [DD10KX] Verification Mode SW Failure Failure code [DHPDKX] Boom head press. sensor circuit
40-248 failure 40-312
Failure code [DD1ALD] Remote positioner upper side set Failure code [DHT1KX] T/M Cut Off pressure sensor
sw failure 40-250 signal Disconnect 40-314
Failure code [DD1BLD] Remote positioner lower side set Failure code [DHT2L6] T/M oil filter sensor circuit failure
sw failure 40-252 40-316
Failure code [DDA7L4] Throttle Lock Input signal Short Failure code [DHT3KX] Transmission main pressure
Circuit 40-254 sensor circuit 40-318
Failure code [DDA8KB] Throttle Lock (set/accelerator) Failure code [DHT4KX] Main PPC oil pressure sensor
switch Short Circuit 40-256 circuit 40-320
Failure code [DDA9KB] Throttle Lock (set/decelerator) Failure code [DHT5KX] Torque converter intake pressure
switch Short Circuit 40-258 sensor circuit 40-322
Failure code [DDB6L4] Neutral Signal Malfunction40-260 Failure code [DHT8KX] Steering Oil Press. Sensor Failure
Failure code [DDD7KA] Speed control dial circuit (Low 40-324
Voltage) 40-262 Failure code [DHTAKX] Transmission lubrication
Failure code [DDD7KB] Speed control dial circuit (High pressure sensor circuit 40-326
Voltage) 40-264 Failure code [DHTBKA] Modulation clutch pressure
Failure code [DDDBKA] Traction control dial circuit (Low sensor circuit Disconnect 40-328
Voltage) 40-266 Failure code [DHTBKB] Modulation clutch pressure
Failure code [DDDBKB] Traction control dial circuit (High sensor signal short circuit 40-330
Voltage) 40-268 Failure code [DHU2KA] F Brake Oil press Sensor
Failure code [DDE5MA] Emergency steering signal Disconnect 40-332
Failure 40-270 Failure code [DHU2KB] F Brake Oil press Sensor Hot
Failure code [DDK4KA] AJSS F/N/R Input Signal short 40-334
Disconnection 40-272 Failure code [DHU2KX] F Brake Oil press Sensor Failure
Failure code [DDK4KB] AJSS F/N/R Input Signal Short 40-336
Circuit 40-274 Failure code [DHU3KA] R Brake Oil press Sensor
Failure code [DDK5L4] Joystick Shift up/down SW circuit Disconnect 40-338
(Disconnect/Short Circuit) 40-276 Failure code [DHU3KB] R Brake Oil press Sensor Hot
Failure code [DDP5KA] Steering lock detector pressure short 40-340
switch signal circuit Disconnect 40-278 Failure code [DHU3KX] R Brake Oil press Sensor Failure
Failure code [DDT4LD] T/M Cut Off set switch signal short 40-341
circuit 40-280 Failure code [DJF1KA] Fuel level sensor circuit
Failure code [DDW9LD] Kickdown Switch Short Circuit Disconnection 40-343
40-282 Failure code [DK30KA] Steering lever angle sensor
Failure code [DGE5KX] Ambient air temp Sensor Failure (Disconnect/Short Circuit) 40-344
40-284 Failure code [DK30KY] Steering lever angle sensor circuit
Failure code [DGF1KA] Transmission Oil Temperature hot short 40-345
sensor signal Disconnect 40-286 Failure code [DK59KA] Boom lever potentiometer (main)
Failure code [DGF1KB] Abnormality in Transmission Oil (Disconnect/Short Circuit) 40-346
Temperature sensor Short Circuit 40-288 Failure code [DK59KY] Boom lever potentiometer (main)
Failure code [DGF1KX] Transmission Oil Temperature hot short 40-348
sensor Failure (For Check) 40-290
WA1200-6 3
Index
Failure code [DK59L8] Boom lever potentiometer (main & Failure code [DW23KB] T/M E-POCV (F bypass)
sub) failure 40-349 Solenoid Short Circuit 40-405
Failure code [DK5AKA] Boom lever potentiometer (sub) Failure code [DW23KY] T/M E-POCV (F bypass)
(Disconnect/Short Circuit) 40-352 Solenoid circuit Hot short 40-406
Failure code [DK5AKY] Boom lever potentiometer (sub) Failure code [DW24KA] T/M E-POCV (R bypass)
hot short 40-354 Solenoid Disconnection 40-407
Failure code [DK5BKA] Bucket lever potentiometer (main) Failure code [DW24KB] T/M E-POCV (R bypass)
(Disconnect/Short Circuit) 40-356 Solenoid Short Circuit 40-408
Failure code [DK5BKY] Bucket lever potentiometer (main) Failure code [DW24KY] T/M E-POCV (R bypass)
hot short 40-358 Solenoid circuit Hot short 40-409
Failure code [DK5BL8] Bucket lever potentiometer (main Failure code [DW25KA] T/M E-POCV (1st bypass)
& sub) failure 40-359 Solenoid Disconnection 40-410
Failure code [DK5CKA] Bucket lever potentiometer (sub) Failure code [DW25KB] T/M E-POCV (1st bypass)
(Disconnect/Short Circuit) 40-362 Solenoid Short Circuit 40-411
Failure code [DK5CKY] Bucket lever potentiometer (sub) Failure code [DW25KY] T/M E-POCV (1st bypass)
hot short 40-363 Solenoid circuit Hot short 40-412
Failure code [DKA0KA] Boom angle sensor Failure code [DW4PKA] Boom EPC solenoid (raise1)
(Disconnect/Short Circuit) 40-364 disconnection 40-413
Failure code [DKA0KX] Boom angle sensor circuit failure Failure code [DW4PKB] Boom Raise EPC solenoid (1)
40-366 ground fault 40-414
Failure code [DKA0KY] Boom angle sensor circuit hot Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot
short 40-368 short 40-415
Failure code [DKA0L0] Boom angle sensor failure 40-370 Failure code [DW4QKA] Boom Lower EPC solenoid (1)
Failure code [DKD0KA] Frame angle sensor disconnection 40-416
(Disconnect/Short Circuit) 40-372 Failure code [DW4QKB] Boom EPC solenoid (take
Failure code [DKD0KY] Frame angle sensor circuit hot down1) short circuit 40-417
short 40-373 Failure code [DW4QKY] Boom EPC solenoid (take
Failure code [DKD0KZ] Frame and steering angle sensor down1) hot short 40-418
failure 40-374 Failure code [DW4RKA] Bucket tilt EPC solenoid (1)
Failure code [DKH0KA] Angle sensor circuit (FR) disconnection 40-419
Disconnect 40-375 Failure code [DW4RKB] Bucket tilt EPC solenoid (1)
Failure code [DKH0KB] Angle sensor circuit (FR) Hot ground fault 40-420
short 40-376 Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot
Failure code [DKH1KA] Angle sensor circuit (LR) short 40-421
Disconnect 40-378 Failure code [DW4SKA] Bucket dump1 EPC solenoid
Failure code [DKH1KB] Angle sensor circuit (LR) Hot disconnection 40-422
short 40-380 Failure code [DW4SKB] Bucket dump EPC solenoid (1)
Failure code [DLE2KA] Engine Speed Sensor short circuit 40-423
Disconnection 40-382 Failure code [DW4SKY] Bucket dump EPC solenoid (1)
Failure code [DLE2LC] Engine Speed Sensor Short hot short 40-424
Circuit 40-384 Failure code [DW5PKA] Boom EPC solenoid (raise2)
Failure code [DLF6LC] Tire speed sensor circuit 40-386 disconnection 40-425
Failure code [DLFAKA] Mod/c Output Speed Sensor Failure code [DW5PKB] Boom Raise EPC solenoid (2)
Disconnect 40-388 ground fault 40-426
Failure code [DLFALC] Mod/c Output Speed Sensor Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot
Short Circuit 40-390 short 40-427
Failure code [DLT4KB] Output Shaft Speed Sensor (1) Failure code [DW5QKA] Boom EPC solenoid (take
Short Circuit 40-392 down2) disconnection 40-428
Failure code [DLT4KX] Output Shaft Speed Sensor (1) Failure code [DW5QKB] Boom Lower EPC solenoid (2)
Disconnection 40-394 ground fault 40-429
Failure code [DT20KB] Transmission cut off indicator Failure code [DW5QKY] Boom Lower EPC solenoid (2)
Output short circuit 40-396 hot short 40-430
Failure code [DT21KB] Speed Control indicator Output Failure code [DW5RKA] Bucket tilt2 EPC solenoid
short circuit 40-397 disconnection 40-431
Failure code [DUM8KB] VHMS Operation lamp Short Failure code [DW5RKB] Bucket tilt EPC solenoid ground
Circuit 40-398 fault 40-432
Failure code [DV00KY] Buzzer circuit hotshort (for Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot
usually) 40-400 short 40-433
Failure code [DV01KY] Buzzer circuit hotshort (for Failure code [DW5SKA] Bucket dump2 EPC solenoid
special) 40-402 disconnection 40-434
Failure code [DW23KA] T/M E-POCV (F bypass) Failure code [DW5SKB] Bucket dump2 EPC solenoid
Solenoid Disconnection 40-404 short circuit 40-435
4 WA1200-6
Index
Failure code [DW5SKY] Bucket dump2 EPC solenoid hot Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid
short 40-436 circuit Hot short 40-481
Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Failure code [DXH7KA] T/M E-POCV (R) Solenoid
Disconnection 40-437 Disconnection 40-483
Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short
Short Circuit 40-438 Circuit 40-485
Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit
circuit Hot short 40-439 Hot short 40-487
Failure code [DWM1KA] Work equipment neutral lock Failure code [DXH8KA] T/M E-POCV (F) Solenoid
solenoid disconnection 40-440 Disconnection 40-489
Failure code [DWM1KB] Work equipment neutral lock Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short
solenoid short circuit 40-441 Circuit 40-491
Failure code [DWM1KY] Work equipment neutral lock Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit
solenoid hot short 40-442 Hot short 40-493
Failure code [DWN6KA] Magnet detent solenoid (Boom Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid
raise) disconnection 40-443 Disconnection 40-494
Failure code [DWN6KB] Magnet detent solenoid (Boom Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid
raise) short circuit 40-444 Short Circuit 40-495
Failure code [DWN6KY] Magnet detent solenoid (Boom Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid
raise) hot short 40-445 Short Circuit to 24 V 40-496
Failure code [DWN7KA] Magnet detent solenoid (Boom Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid
float) disconnection 40-446 Malfunction 40-497
Failure code [DWN7KB] Magnet detent solenoid (Boom Failure codes table 40-27
float) short circuit 40-447 Final drive 10-66, 60-36
Failure code [DWN7KY] Magnet detent solenoid (Boom Flushing procedure for brake circuit 50-54
float) hot short 40-448 Flushing procedure for torque converter and transmission
Failure code [DWN8KA] Magnet detent solenoid (Bucket circuit 30-32
tilt) disconnection 40-449 Flushing procedure for work equipment and steering
Failure code [DWN8KB] Magnet detent solenoid (Boom circuit 50-60
tilt) short circuit 40-450
Failure code [DWN8KY] Magnet detent solenoid (Boom H
tilt) hot short 40-451 H-1 Torque converter oil temperature rises too high
Failure code [DWNAKA] NC solenoid disconnection (overheats) 40-702
40-452 H-2 Turning or response of steering is poor 40-705
Failure code [DWNAKB] NC solenoid short circuit 40-453 H-3 AJSS lever is hard to operate 40-708
Failure code [DWNAKY] NC solenoid hot short 40-454 H-4 Steering shakes or jolts 40-710
Failure code [DXA1KA] Loader pump solenoid Relay H-5 Wheel brake does not work at all or is weak 40-712
(Disconnect/Short Circuit) 40-455 H-6 Lift arm speed is low or lift arm rising force is
Failure code [DXA1KY] Loader pump solenoid Relay hot insufficient 40-714
short 40-457 H-7 Shock is large when lift arm stops 40-717
Failure code [DXA1MA] Loader pump solenoid Relay H-8 Hydraulic oil temperature rises too high (overheating)
(Disconnect/Short Circuit) 40-459 40-718
Failure code [DXF0KA] AJSS EPC solenoid Handling of electric equipment 00-30
disconnection 40-461 Handling of hydraulic components 00-25
Failure code [DXF0KB] AJSS EPC solenoid short circuit How to measure play of center hinge bearing 30-36
40-463 How to read Disassembly and Assembly 50-4
Failure code [DXH4KA] T/M E-POCV (1st) Solenoid How to read electric wire code 00-40
Disconnection 40-465 How to read the shop manual 00-21
Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Hydraulic piping drawing of torque converter and
Circuit 40-467 transmission 10-13
Failure code [DXH4KY] T/M E-POCV (1st) Solenoid Hydraulic piping layout drawing 10-133
circuit Hot short 40-469 Hydraulic tank 10-136
Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid
Disconnection 40-471
Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid I
Short Circuit 40-473 Information contained in troubleshooting table (H mode)
Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid 40-701
circuit Hot short 40-475 Information in troubleshooting table 40-44
Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Initial setting procedure for KOMTRAX Plus controller
Disconnection 40-477 30-148
Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Initial setting procedure for remote boom positioner (origin
Circuit 40-479 input method) 30-131
Inspection and maintenance of KOMTRAX Plus controller
30-147
WA1200-6 5
Index
Interview and confirmation of failure symptom 80-31 R

Receiver drier 80-22
J Releasing remaining pressure in hydraulic circuit 30-122
Jack-up point 10-132 Relief valve 10-179
50-404
L
Removal and installation of air-cooled torque converter
Layout drawing of connector pins 40-48
and transmission, and brake oil cooler assembly 50- 86
List of abbreviation 00-50
Removal and installation of brake accumulator charge
Lubrication relief valve 60-23
valve assembly 50-265
Removal and installation of brake oil tank assembly
M 50-266
Machine monitor system 10-196 Removal and installation of bucket cylinder assembly
Main relief valve and torque converter relief valve 10-24 50-304
Main relief valve, torque converter relief valve 60-14 Removal and installation of bulkhead assembly 50-396
Measurement procedure by downloading data in Removal and installation of bumper and fuel tank
KOMTRAX Plus controller 30-173 assembly 50-98
Measurement procedure by multi monitor 30-177 Removal and installation of center hinge pin 50-268
Measuring engine oil pressure 30-17 Removal and installation of center support assembly
Measuring exhaust gas temperature 30-18 50-251
Measuring point of hydraulic pump oil pressure 30-91 Removal and installation of controller assembly 50-443
Measuring wear of rear axle support 30-38 Removal and installation of damper assembly 50-89
Measuring wind speed across radiator and oil cooler Removal and installation of differential assembly 50-223
30-21 Removal and installation of DT connector pin 50-439
Mesuring wear of wheel brake disc 30-61 Removal and installation of emergency diverter valve
Method of disconnecting and connecting push-pull type assembly 50-262
coupler 00-27 Removal and installation of emergency steering pump
Method of releasing parking brake manually 30-78 assembly 50-264
Multi-function monitor 10-224 Removal and installation of engine assembly 50-79
Removal and installation of front axle assembly 50-205
N Removal and installation of front final drive assembly
Neutral cutoff solenoid valve (NC valve) 10-177 50-207
nitrogen gas 30-80 Removal and installation of HD connector pin 50-441
No.1 work equipment pump 60-59 Removal and installation of hood assembly 50-100
No.2 work equipment pump 60-62 Removal and installation of hydraulic tank, filter case
assembly 50-284
Removal and installation of lift cylinder assembly 50-315
O Removal and installation of No. 1 work equipment pump
Operation test of work equipment valve by work assembly 50-286
equipment speed (speed of work equipment is low) Removal and installation of No. 2 work equipment pump
30-107 assembly 50-288
Outline of measurement procedure for Pm Clinic 30-236 Removal and installation of operator's cab and floor
Outline of refrigeration cycle 80-6 assembly 50-398
P 50-402
Parking brake 10-123, 60-52 Removal and installation of parking brake assembly
Parking brake solenoid valve 10-124 (installed on the machine) 50-197
Parts replacement 80-50 Removal and installation of radiator and hydraulic oil
Periodic inspection and maintenance 80-53 cooler assembly 50-72
Pm clinic service 30-238 Removal and installation of rear axle assembly 50-209
Power train 10-11 Removal and installation of rear final drive assembly
PPC relief valve 60-65 50-220
Precautions for refrigerant 80-3 Removal and installation of steering cylinder assembly
Precautions for replacing KOMTRAX Plus controller 50-258
30-165 Removal and installation of steering demand valve
Precautions when performing work 00-43 assembly 50-257
Preparation for measurement for Pm Clinic 30-237 Removal and installation of steering pump, control pump
Procedure for disconnecting front frame and rear frame and PPC pump assembly 50-202
50-267 Removal and installation of switch pump assembly
Procedure for running in bucket pin 50-391 50-289
Procedure for running in lift arm pin 50-393 Removal and installation of torque converter and
Procedure for testing diodes 30-137 transmission assembly 50-113
Pump control relief valve 60-66
6 WA1200-6
Index
Removal and installation of transmission, brake cooling Testing and adjusting steering main relief valve oil
device and brake pump assembly 50-201 pressure 30-54
Removal and installation of water-cooled torque converter Testing and adjusting steering oil pressure 30-39
and transmission oil cooler assembly 50-88 Testing and adjusting steering stopper bolt 30-44
Removal and installation of work equipment assembly Testing and adjusting steering surge cut valve oil
50-335 pressure 30-52
Removal and installation of work equipment control valve Testing and adjusting torque converter and transmission
assembly 50-290 oil pressure 30-26
Repairing HD connector pin harness 50-442 Testing and adjusting work equipment oil pressure by
Retrieval of disabled machine due to transmission valve using multi monitor 30-86
failure 30-33 Testing and adjusting work equipment oil pressure by
Rotary valve 10-99 using oil pressure gauge 30-88
S 30-89
Safety notice 00-16 Testing and adjusting work equipment pump TVC valve
Safety precautions to follow before starting work 30-9 oil pressure 30-105
Sensor 10-357 Testing and adjusting work pump CO (cut-off) valve oil
Sequence of events in troubleshooting 40-9 pressure 30-101
Service tools 80-23 Testing blow-by pressure 30-16
Setting method of auto grease timer 30-126 Testing brake accumulator oil pressure leakage 30-64
Sketches of special tools 50-14 Testing brake cooling oil pressure 30-74
Slack adjuster 10-120, 60-50 Testing brake oil cooler performance 30-76
Special functions of multi monitor 30-179 Testing brake performance 30-58
Special tool list 50-9 Testing brake valve oil leakage amount 30-69
Specification dimension drawing 01-3 Testing emergency parking brake valve oil leakage
Specifications 01-4 amount 30-66
Standard tightening torque table 00-46 Testing engine speed 30-13
Standard value table for chassis 20-4 Testing exhaust gas color 30-15
Standard value table for engine 20-3 Testing hydraulic oil cooler performance 30-114
Steering cylinder 60-45 Testing intake air pressure (boost pressure) 30-19
Steering cylinder mount 60-44 Testing lowering of wheel brake oil pressure 30-59
Steering demand valve 10-89, 60-41 Testing of slack adjuster 30-60
Steering equipment layout drawing 10-67 Testing parking brake oil pressure 30-79
Steering lock valve 10-107 Testing parking brake performance 30-76
Steering oil pressure group 40-610 Testing radiator performance 30-20
Steering oil pressure system, general 40-609 Testing rotary valve output pressure 30-56
Steering pump 10-70, 60-38 Testing steering EPC valve 30-50
Switch pump 10-72, 60-39 Testing torque converter oil cooler performance 30-30
Symptom and troubleshooting numbers 40-8, 40-43 Testing wear of parking brake disc 30-77
Testing work pump ES valve output pressure 30-99
Tools for testing, adjusting, and troubleshooting 30-4
T Torque converter 10-15, 60-10
T- branch box and T- branch adapter table 40-104 Torque converter oil cooler 10-59
Table of fuel, coolant and lubricants 01-9 Torque converter pump, transmission pump, brake
Table of fuse locations 40-107 cooling pump, brake pump 60-26
Testing accumulator nitrogen gas pressure and Torque converter regulator valve 10-27, 60-16
procedure for charging accumulator with nitrogen gas Traction control function checking procedure 30-29
30-80 Transfer 10-57, 60-24
Testing additional cooler fan speed 30-31 Transmission 10-35, 60-18
Testing and adjusting accumulator charge pressure Transmission control system 10-315
30-62 Transmission control valve 10-46, 60-20
Testing and adjusting air conditioner compressor belt Transmission hydraulic circuit diagram 90-6
tension 30-23 Transmission lubricating oil relief valve 10-56
Testing and adjusting bucket proximity switch 30-128 Transmission mount 60-8
Testing and adjusting compressor belt tension 80-57 Troubleshooting 80-33
Testing and adjusting differential valve output oil pressure Troubleshooting for unusual noise 80-47
30-97 Troubleshooting method for open circuit in wiring harness
Testing and adjusting emergency steering oil pressure of pressure sensor system 40-46
30-40 Troubleshooting procedures 80-30
Testing and adjusting fan belt tension 30-22
30-134
W
Testing and adjusting PV control relief valve oil pressure Weight table 01-7
30-95 Work equipment and AJSS control system 10-277
WA1200-6 7
Index
Work equipment control lever 10-312, 60-77

Work equipment control lever linkage 10-135
Work equipment control valve 10-181, 60-67
Work equipment cylinder 60-75
Work equipment hydraulic circuit diagram 90-11
Work equipment hydraulic system, general 40-528
Work equipment linkage 10-194, 60-69
8 WA1200-6
DRAFT
Shop Manual
DRAFT
WA1200-6 WHEEL LOADER
Form No. SEN05475-04
©2012 KOMATSU
All Rights Reserved
Printed in Japan 07-12

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SEN05475-04

WHEEL LOADER WA1200 -6

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List of revised pages

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Machine model Serial number

00 Index and foreword 0 -1

00 Index and foreword

10 Structure and function

Diverter valve....................................................................................................................... 10- 103

20 Standard value table

30 Testing and adjusting

Testing blow-by pressure..................................................................................................... 30- 16

Failure code [DB2RKR] Communication Lost Engine Controller......................................... 40- 216

50 Disassembly and assembly

Flushing procedure ................................................................................................................. 50- 54

Undercarriage and frame ........................................................................................................ 50- 267

Steering cylinder mount ....................................................................................................... 60- 44

90 Diagrams and drawings

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

Foreword and general information 0 -16

4. Precautions for slinging work and making

4)Check the direction indicator plates (east,

How to read the shop manual 0 -21

1. Composition of shop manual

00. Index and foreword

10. Structure and function

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

60. Maintenance standard

2. Revision and distribution

Symbol Item Description

Special technical precautions or other precautions for preserving standards which

Explanation of terms for maintenance standard 0 -23

qUsually, the dimension of a hole and the dimen-

4. Repair limit and allowable value or allowable

Handling of hydraulic components 0 -25

1. Be careful of the operating environment

2. Disassembly and maintenance work in the

4. Preventing intrusion of foreign materials

5. Replacing hydraulic oil while its temperature is high

Method of disconnecting and connecting push-pull type coupler 0 -27

Handling of electric equipment 0 -30

Points to remember when handling electric equipment 0 -30

4)High-pressure water entering connector

3. Removing, installing, and drying connectors

2]When removing from clips

qWhen removing a connector from a clip,

3]Action to take after removing connectors

3)Deutsch connector (DT 8-pin, 12-pin)

4)Drying wiring harness

2]Dry the inside of the connector with a dryer.

3]Perform a continuity test on the connector.